Wallace & Tiernan® Instruction Manual

MICRO/2000® and DEOX/2000® Measurement Module

W3T331759 / WT.050.585.003.UE.IM. 1014

Suite 3, 2nd Floor, One 60 London Road, Sevenoaks, TN13 1BT

Tel.: +44 1732 771777 Fax: +44 1732 771800 www.evoqua.com

Important Notice
Evoqua Water Technologies Instruction Manuals are the safety documents for their products. The information provided therein
is in accordance with the best practices known at the time of issue and, if fully implemented, should enable the user to operate
the plant in the safest possible manner. It is therefore most important that instructions be read and understood prior to the
installation, operation or maintenance of the plant.

Notes Warranty
Where necessary, special instructions are provided and are The equipment supplied is guaranteed against mechanical
quoted under the following headings: defect notified to the Seller within a period of 1 year from
the date of delivery. For such guarantee to be valid the
WARNING: A warning is given in instances where purchaser must notify the seller in writing immediately
failure to observe the instruction could result in injury to such defect becomes apparent. If the Seller so requires,
personnel. the Purchaser shall return the defective equipment (at the
Purchaser’s expense) to the Seller. The Seller undertakes
CAUTION: Cautions are given where failure to that it will, at its own option and its own expense, and by way
observe the instruction may result in equipment damage, of full discharge of its guarantee obligation hereunder, either
or pollution to an allied system.
repair, or supply a replacement for the defective equipment,
or refund any purchase monies paid to it in respect of any
NOTE: Notes are provided to give additional emphasis to
such defective equipment, or portion thereof. If title to the
particular points of detail.
defective equipment is at the time of such replacement or
The following recommendations are made to ensure safe refund vested in the Purchaser, then title shall thereupon
and efficient operation:- vest in the Seller. Replacement material situated outside
the U.K. will be supplied F.O.B. U.K. Port. The guarantee
1 Only suitably qualified personnel should install, operate given in this clause shall not be operative and enforceable
and maintain the equipment. if the equipment is not operated strictly in accordance
with the sellers instruction, or in the respect of any defect
2 Only Evoqua Water Technologies manufactured or arising from accident, deliberate act, misuse, neglect or
approved parts should be used. from a breach from the terms of the following clause, or
in respect of any defect arising through damage incurred
3 The equipment should not be used for any purpose other while being transported after delivery of the equipment, or if
than that for which it was supplied. the equipment has been altered or modified in any way by
any person other than the seller, or in respect of any other
4 If equipment being supplied is being put into storage or cause whatsoever which lies beyond the Sellers control.
not being commissioned immediately, or if the plant is being
de-commissioned, Evoqua Water Technologies urge that The Purchaser must comply with all user instructions
they be contacted for detailed advice. and safety recommendations issued by the Seller, and
must install, commission and maintain the equipment in
In an effort to make progressive improvements to products, accordance with good engineering practice, and under the
changes in design may be incorporated from time to time, which supervision of suitably qualified personnel, and the Seller
may not be reflected immediately in the instruction manual.
shall not be liable to the Purchaser for any loss suffered
If in doubt, contact Evoqua Water Technologies quoting the
as a result of the Purchaser’s breach of the terms of this
equipment serial number; serial numbers are essential for
clause.
effective communication and proper equipment identification.

The equipment described in this manual may be used with Subject to this guarantee all conditions, warranties and
substances that themselves may be hazardous to personnel representations, whether expressed or implied (by statute
safety. It is essential that persons employed in the vacinity of or otherwise) relating to the equipment, are hereby excluded
such substances be aware of the appropriate safety practices in so far as they can be excluded without such exclusion
and the location of suitable safety equipment. Provision of being void or unenforceable at law.
safety cards and codes of practice concerning hazardous
substance should be made by the supplier of the substance.

Wallace & Tiernan, Barrier, Chem-Ad, DEPOLOX, OSEC, and V10k are trademarks of Evoqua, its subsidiaries or affiliates.

The designations used in this publication may be trademarks whose use by third parties for their own purposes could
violate the rights of the owners.All rights, especially those to duplication and distribution as well as translation, are
reserved. No part of this document may be reproduced in any form (printing, photocopying, microfilm or any other
method) or saved, processed, duplicated or distributed by the use of electronic systems without the express written
consent of Evoqua Water Technologies.
 International Contact Information

Area Phone email

Australia +61 (0) 3 8720 6597 [email protected]

Canada +1 905 944 2800 [email protected]

Germany +49 8221 9040 [email protected]

Singapore +65 8630 7100 [email protected]

U.S.A. +1 856 507 9000 [email protected]

U.K. +44 (0) 1732 771777 [email protected]

 MICRO/2000® AND DEOX/2000® MODULE

INTRODUCTION

The MICRO/2000® and DEOX/2000® Residual Analyser utilises the same

robust measurement system with different set of chemical reagents to cover
the full range of analytical measurements. The unit consists of a peristaltic
pump, which delivers sample and reagents, a measuring cell and probe. The
system is designed to continually measure the level of free or total
chlorine residual present in a flow of water and, by control of the chlorine
dosage rate, maintain a predetermined chlorine residual level in the treated
water. The MICRO/2000® and DEOX/2000® can also be used to control
levels of chlorine dioxide or potassium permanganate in a flow of water.

In a MICRO/2000® configuration, the peristaltic pump ensures a consistent

flow of sample water to the cell where the residual is measured. Where
required for pH buffering and/or total residual measurement, the pump also
delivers liquid reagents in fixed proportion to the sample. Potassium iodide
liquid reagent must be added to the analyser sample for the measurement
of total chlorine residual and acetate buffer to ensure that the sample pH
is maintained at pH 4. See Appendix A for further information on the
reagents. The system can be used for residuals in potable water, primary
or secondary wastewater or cooling water

In a DEOX/2000® system it operates as a centre zero analyser capable

of measuring oxidants (Chlorine and Ozone) and reductants (Sulphur
Dioxide). Potassium Iodide and Potassium Iodate are mixed with Acetic
acid to form Iodine in a mixing coil. This is then injected into the sample
stream and subsequently measured as a reduction current by the probe.
The presence of oxidant in the sample stream causes excess Potassium
Iodide to be oxidised to Iodine resulting in an increase in the measured
reduction current, whilst the presence of a reductant in the sample stream
results in the removal of Iodine and hence a reduction in the measured
current. Simply, changes above or below the measured Iodine baseline
enable the unit to detect both oxidants and reductants. See Appendix B
for further information on the reagents. The system can be used for all
dechlorination applications.

This manual has been produced to enable the user to obtain maximum service
from the equipment and comprises installation, operation, maintenance and
spare parts information. Minor changes may be made to the equipment
that are not immediately reflected in the manual - if such a change appears
to have been made, contact Evoqua Water Technologies for information.
Our guarantee is conditional upon the equipment being used in accordance
with the instructions herein and we therefore recommend that they be read
and fully understood before the equipment is placed in service.

Evoqua Water Technologies

W3T331759 / WT.050.585.003.UE.IM.1014 1
 MICRO/2000® AND DEOX/2000® MODULE

Intended Use

The MICRO/2000® and DEOX/2000®Analyser are exclusively designed

for measurement and control tasks in conjunction with the SFC or MFC
controllers when required for the treatment of waste water, potable water
and industrial water.

The operational safety of the unit is only guaranteed if it is used in

accordance with its intended application. The unit may only be used
for the purpose defined in the order and under the operating conditions
indicated in the technical specifications.

Compliance with the intended use also includes reading this operating
manual and observing all the instructions it contains. All inspection and
maintenance work must be performed at the prescribed intervals by
qualified personnel.

The operator bears full responsibility if this unit is put to any use which
does not comply strictly and exclusively with the intended use.

Table Of Contents

General Safety Precautions

Technical Data 1
Installation 2
Setup and Control Functions 3
Operation 4
Maintenance 5
Illustrations 6
Spare Parts List 7
MICRO/2000® Reagents Appendix A
DEOX 2000 Reagents Appendix B

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GENERAL SAFETY INSTRUCTIONS

Evoqua Water Technologies attaches great importance to ensuring work

on it's system is safe. This is taken into account in the design of the
system, by the integration of safety features.

Safety Instructions

The safety instructions in this documentation must always be observed. These

do not impact on any additional national or company safety instructions.

Safety Instructions on the System

All safety instructions attached to the system itself must be observed.

Technical Standard

The system or unit has been constructed in accordance with state-of-

art technology and the accepted safety regulations. In the event of the
system, or unit, being used by persons who have not been adequately
instructed, risks hazard to such persons or third parties and damage to the
system or unit itself or to other property are possible. Work described in
this operating manual may only be performed by authorized personnel.

Personnel

The operator of the system must ensure that only authorized and qualified
specialized personnel are permitted to work with and on the unit within
their defined scope of authority. "Authorized specialists“ are trained
technicians employed by the operator, by Evoqua Water Technologies,
or, if applicable, the service partner. Only qualified electricians may
perform work on electrical components.

Spare Parts/Components

Trouble-free operation of the system is only guaranteed if original spare

parts and components are used as described in this operating manual.
Failure to observe this instruction may incur the risk of malfunction or
damage to the system.

Modifications and Extensions

Never attempt to perform any modifications or conversions to the unit

without the written approval of the manufacturer.

W3T331759 / WT.050.585.003.UE.IM.1014 3
 MICRO/2000® AND DEOX/2000® MODULE

Electrical Power

During normal operation, the control unit must remain closed. Before
starting any assembly, inspection, maintenance, or repair work, the
system must be switched OFF, and the isolator must be secured against
reactivation. Connect all cables in accordance with the wiring diagram.

Waste Disposal

Ensure safe and environmentally-friendly disposal of reagents and

replaced part

Warranty Conditions

The following must be observed for compliance with warranty conditions:

• Installation, commissioning by trained and authorized personnel.

• Intended use.
• Observation of the operational parameters and settings.
• The unit may only be operated by trained personnel.
• An operating log book must be kept.
• Only approved calibration chemicals may be used.
• The unit must not be exposed to ambient conditions outside those
specified.
• Maintenance work must be executed at recommended intervals.
• Use of original Evoqua Water Technologies spare parts.

If any of the above conditions are not met, the warranty could be void.

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 MICRO/2000® AND DEOX/2000® MODULE

SPECIFIC OPERATING PHASES

Normal Operation

Never employ procedures which could affect safety.

Only operate the unit when the housing is closed.

Inspect the unit at least once daily for externally visible damage and faults.
Inform the responsible person/authority immediately of any detected
changes (including any changes in the operating performance).

In the event of malfunctions, switch the unit off immediately. Have

malfunctions remedied immediately.

Installation and Maintenance Work

Always perform installation or maintenance work in accordance with

this operating manual.

Secure the unit against activation during installation and maintenance

work.

Always retighten released screw connections.

Never use corrosive cleaning agents. Use only a damp cloth to clean
the unit.

Ensure safe disposal of reagents and replaced parts in accordance with

environmental regulations.

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1 TECHNICAL DATA

List of Contents
Section
Specifications 1.1
MICRO/2000® and DEOX/2000®
Flow block assembly 1.1.1
Electrodes and Sensors 1.1.2
Scope of Supply 1.2
Standard 1.2.1
Description 1.3
Versions 1.3.1
Design 1.4
Electronic module 1.4.1
MICRO/2000® and DEOX/2000®
flow block assembly 1.4.2

1.1 Specifications

MICRO/2000® and DEOX/2000® measuring module for disinfectant

(Micro/2000®) and chlorination/dechlorination (DEOX/2000®)

Sensor input: 3 electrode cell

Principle of operation: Potentiostatic amperometry
Temperature drift: < 0.2 %
Linearity error: < 0.1 %
Cell voltage: 250 mV
Cell current: 1 to 7 μA/mg/l
Temperature input: PT 1000
Measuring range 0.100, 0.200, 0.500, 1.00, 2.00, 5.00,
(MICRO/2000®): 10.0, 20.0, 50.0, 100, 200
Units of measure μg/l, mg/l
(MICRO/2000®):
Measuring range
(DEOX/2000® - defined as -0.50 - +0.50, -1.00 - +1.00,
dechlorination value (-) to -2.00 - +2.00, -2.50 - +2.50,
chlorination (+)) -5.00 - +5.00, -10.0 - +10.0
Units of measure
(DEOX/2000®): mg/l
Measurands (MICRO/2000®): Free chlorine, total chlorine, chlorine
dioxide, potassium permanganate, ozone
Measurands (DEOX/2000®): Sulphur dioxide - total chlorine
Sodium bisulphite - total chlorine
Sensitivity: MICRO/2000® - 0.001 µg/l or 1 %

W3T331759 / WT.050.585.003.UE.IM.1014 7
 MICRO/2000® AND DEOX/2000® MODULE

full scale (whichever is greater)

DEOX/2000® - 0.01 mg/l or 5 %
full scale (whichever is greater)
Protection Category: CE Version Enclosure - (IP 66), CE
(NEMA 4X)
Power Supply: 230V ± 10%, 50/60 Hz, 15W;
Fuse - 200 mA, 5 x 20 mm, fast acting
Operating Conditions: Ambient temperature 2 to 52°C
(35 to 125°F )
Sample Temperature -3 to 52°C
(26 to 125°F )
Storage Temperature -16 to 70°C
(4 to 158°F )

1.1.1 MICRO/2000® and DEOX/2000® flow block assembly

Housing
Facade Dimensions: (W x H x D) mm: 330 x 330 x 254
Weight: approx.: 9.1 kg

Connections
Sample water: 6mm OD (¼") hose
Thread connection: 13mm (½")

Flow control valve (to sample inlet water line accessories)

Flow rate: MICRO/2000® - approx. 3.8 to 11.4 l/m
(1 to 3 US gpm)
DEOX/2000® - approx. 7.6 to 19 l/m
(2 to 5 gpm)
Control range: 0.2 to 4.0 bar (3 to 58 psi)
Back-pressure: 0 bar (0 psi) (free drain)

Sample water
Water quality: ultra pure, potable, industrial, municipal
and industrial waste, dechlorinated waste
(DEOX/2000®)
Sample water
temperature: max. 50 °C (122 °F)

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1.1.2 Electrodes and sensors

MICRO/2000® and DEOX/2000® 3-electrode measuring cell

Measuring system: 3-electrode sensor with additional
stock of electrolyte salt
Principle of operation: potentiostatic amperometry
Temperature
compensation: 0 to 50°C (32 to 122°F)
Temperature drift: max. 0.2 % / 10°C
Measuring range: MICRO 2000: 100 μg/l - 200 mg/l
DEOX 2000: ±0.50 mg/l - ±10.0 mg/l
Upot: 0 to 1000 mV
Reference electrode: silver/silver halide/potassium halide
solution
Working electrode: platinum
Storage temperature: -10 to 30°C (14 to 86°F)
Max. pressure: 0.4 bar (5 psi) at pump suction
Water quality: clean water, potable water quality,
municipal & industrial waste, seawater
Flow: 7.6 l/h (2 US g/h), as constant as possible,
into sample line
Service Life: life of the electrodes in operation
approx. 3-5 years
Cross-sensitivity: ozone, bromine, chlorine dioxide,
hydrogen peroxide, strong oxidants

1.2 Scope of Supply

1.2.1 Standard
Depending on the individual order, the scope of supply includes the
following:

Electronic module including accessories set and mounting set, comprising of:

• 4 x screws Ø 5mm
• 4 x dowels Ø 8mm
• 4 x washers
• 3 multiple seal inserts 2 x 6mm
• 3 multiple seal inserts 4 x 5mm
• 3 reducing sealing rings Ø 8mm
• 4 bolts for multiple seal inserts 5mm
• 2 bolts for multiple seal inserts 6mm
• DIN rail

W3T331759 / WT.050.585.003.UE.IM.1014 9
 MICRO/2000® AND DEOX/2000® MODULE

1.3 Description
1.3.1 Versions

The SFC and MFC are available in two different versions (see section 3.1,
"Versions), each in two voltage variations:

• 110 to 230 VAC

Depending on the application, they can be operated either without a flow

block assembly (no sensor measuring module) or in conjunction with a
flow block assembly and sensor measuring module.

Flow Block Assembly

The flow block assembly is available as below:

• MICRO 2000
• DEOX 2000

A Cover
B Cell body with sensor
C Peristaltic pump
D Inlet shut-off valve
E Bypass Y-strainer with
flow control valve
F Inlet control valve
G Drain hose

Figure 1.1

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1.4 Design
1.4.1 Electronic module

The electronic module consists of a plastic housing with a removable cover.

The housing contains:

• IC board
• housing ducts for the cables of the sensor measuring modules
• the cable glands
• the sensor measuring module (optional)

A IC board D
B Cable glands
C Housing ducts for the cables
of the sensor measuring A
modules
D Slot for sensor measuring
module
C
E Housing

Figure 1.2 - SFC basic with card and cable

1.4.2 MICRO/2000® and DEOX/2000® flow block assembly

The MICRO/2000® and DEOX/2000® flow block assembly contains

the following:

• Cell body with cover

• Flow control valve (mounted externally)
• By-pass strainer (mounted externally)
• Shut-off valve (mounted externally)
• 3 electrode probe for free and total chlorine, chlorine dioxide, ozone,
potassium permanganate, sulphur dioxide, sodium bisulphite
• Drain

The cell body can be equipped with one sensor.

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 MICRO/2000® AND DEOX/2000® MODULE

A Cover
B Cell body with sensor
C Peristaltic pump
D Inlet shut-off valve
E Bypass Y-strainer with
flow control valve
F Inlet control valve
G Drain hose

Figure 1.3

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2 INSTALLATION

List of Contents

Section
Transport and Storage 2.1
Transport 2.1.1
Storage 2.1.2
Installation 2.2
Opening the housing 2.2.1
Installation with mounting rail 2.2.2
Installation without mounting rail 2.2.3
Commissioning 2.3
Installation guide 2.3.1
Pour in the cell sand 2.3.2
Insert the sensors and connect 2.3.3
Installing reagent hardware 2.3.4
Connecting the sample water 2.3.5
Connect the device to the power supply 2.3.6
Mounting the housing covers 2.3.7
System Shut Down 2.4
Illustrations
Dimensions
Top Hat Rail Assembly,
MICRO/2000® and DEOX/2000® Flow Block 50.590.100.050
Wall Mount Assembly, MICRO/2000® and
DEOX/2000® Flow Block 50.590.100.060
SFC Schematic Wiring 50.585.155.050A
MFC Schematic Wiring 50.585.155.050B
SFC Sensor Module Connection 50.585.155.050F

2.1 Transport and Storage

2.1.1 Transport

The unit is supplied in standard packaging. During transport the packaged

unit must be handled carefully and should not be exposed to wet weather
or moisture.

Check that the transport packaging is undamaged. In the event of damage

please inform the transport company immediately.

If the device is damaged, please contact the respective Evoqua Water

Technologies immediately. Keep the packing until the unit has been
correctly installed and put into operation.

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 MICRO/2000® AND DEOX/2000® MODULE

2.1.2 Storage

Store the unit and the sensors in a dry condition without any residual water
in a dry place. Storage temperature, see section 1.1, "Specifications".

2.2 Installation

The device must be protected against rain, frost and direct sunlight and
should not be installed outdoors. It must be mounted horizontally on a
flat wall with an ambient temperature of 0 to 50°C (32 to 122°F). The
air in the room should be non-condensing.

2.2.1 Opening the housing

1. Remove the housing cover of the flow block assembly.

2.2.2 Installation with mounting rail (see drawing 50.590.100.050)

1 Fasten the mounting rail to the wall with two screws.

2. Hook the flow block assembly onto the mounting rail to the left of
the electronic module and fasten to the wall with two screws.

CAUTION: The flow block assembly does not need to be mounted

directly next to the electronics, it can be mounted on separate mounting
rail. The exact location limited by available probe cable lengths.

2.2.3 Installation without mounting rails

When wall mounting the unit it should be screwed to a flat surface through
the holes in the corners of the casing, the hole centres for the mounting
being 254 mm x 254 mm.

2.3 Commissioning
2.3.1 Installation guide

Commissioning procedure:

Refer to manual W3T168777 for SFC and manual W3T159207 for the
MFC.

2.3.2 Pour in the cell sand

Adding grit to MICRO/2000® and DEOX/2000® flow block.

a. Remove probe from sample cell.

b. Wet finger tip.

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 MICRO/2000® AND DEOX/2000® MODULE

c. Insert wet finger into supplied grit tube (see Figure 2.1). Some grit
will cling to tip of wet finger (see Figure 2.2).

d. Dip finger into sample cell water, grit will rinse into flow (see
Figure 2.3).

e. Replace probe in sample cell.

NOTE: All the grit in the sample cell should be in suspension, any not
in suspension should be removed.

Figure 2.1 Figure 2.2 Figure 2.3

2.3.3 Insert the sensor and connect

1. Remove the protection cap from the sensor.

2. Install sensor in the cell body cover.

NOTE: Keep the dust protection cap and watering caps of the sensor
for subsequent use.

Arrangement of the plug-in cards and cables:

H
G
F A
B
E C
D

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 MICRO/2000® AND DEOX/2000® MODULE

A IC board
B Housing
C Relay terminal
D Sensor cable duct
E Terminal signal inputs/outputs
F Sensor measuring module
G Coding switch IC board
H Connecting plug or terminal at the front panel board

Figure 2.4 - Electronic Module Cutaway

Connecting the sensor cables:

1. Place the sensor cables with the attached glands into the cable ducts
of the housing.

2. Depending on the sensor design, either plug or screw the cable in place.

3. Insert the supplied bushes into ducts that are not in use in order to
seal housing.

4. It is recommended the cable glands in the bottom of the housing be

used for routing the MICRO/2000® and DEOX/2000® sensor cable.

2.3.4 Installing reagent hardware (See Dwg. 50.505.020.010)

WARNING: To avoid possible severe personal injury or equipment

damage, do not service the metering pump while power is applied to the
pump. The motor has enough torque to cause severe pain and injury if
fingers are caught in the pumping mechanism.

WARNING: To avoid possible severe personal injury or equipment

damage, do not remove the pump occlusion ring while there is any water
pressure at the inlet to the analyser. If the pump occlusion ring is removed
while pressure is applied to the pump, water (possibly containing acid
reagents) can be sprayed from the discharge side of the pump. Sprayed
water may result in damage to the equipment or personal injury as it may
contain some reagent or may be contaminated.

NOTE: It is recommended that water-flow to the wetside should be

blocked and the reagent reservoirs are not filled until installation is
complete. The metering pump may be operated/tested without reagents
or water without damage; however, it is advisable to pour enough water
into the cell to cover the impeller (mixer) before powering the unit to
prevent damage to the impeller shaft seal caused by running the unit dry.

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 MICRO/2000® AND DEOX/2000® MODULE

Before attaching the reagent bottle mounting brackets to mounting surface,

install the retaining strap through the slots in the bracket. The brackets
should be located within 1.2m (4 feet) of the analyser.

• Install the reagent tubing as follows:

Uncoil the reagent tubing segment(s) (one per liquid reagent) and
remove the rigid tubing segments (1/32-inch O.D., 330mm long
(13-inch long)) from the protective packaging. Using two of the
three tubing segments, firmly insert one rigid tube into one end of
each piece of flexible tubing. Then insert the exposed rigid end into
the small hole in the cap of each of the reagent bottles mounted in
the bottle brackets. Route the tubing under the facade and connect
to the pump reagent tubes.

• For information on installing or replacing reagent tube units, refer

to section 5.2.4, "Pump Tubing Units Replacement".

• Tubing Connections:

Cut the excess reagent tubing and connect to the reagent fittings
at the inlet to the reagent tube units.

Install the “T” fitting provided in the tubing at the inlet to (bottom of)
the analyser metering pump. To do this, cut the tubing about 25mm
from the entrance to the pump and reconnect the tubing using the “T”
fitting. This will leave the middle (small) end of the fitting unused.

• If two reagent tube units (two liquid reagents) are used:

Install two, one-inch segments of the reagent tubing, cut from

the 2.4m (8 foot) segment of reagent tube, on the fittings at the
discharge (upper) end of the reagent tube units and join the two
segments with the “Y” fitting provided.

Using approximately 175mm (7 inches) of reagent tubing, connect the

reagent discharge fitting to the tee fitting at the pump sample intake.

2.3.5 Connecting the sample water

MICRO/2000® and DEOX/2000® water sample and sample line

requirements:

Actual requirements will vary with the equipment application, but the
following should be used as general guidelines. Sample plumbing design
is the most important part of a reliable monitoring system.

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 MICRO/2000® AND DEOX/2000® MODULE

A well-designed sampling system minimizes response time, prevents

fouling of the sample line plumbing and the analyser, and provides a
fully developed turbulent flow to the analyser.

Response time is minimized by locating the analyser close to the point of

sample take-off and by designing for a moderately high flow velocity in
the sample line, 1.5 m/s (5 ft/sec). Flow velocity also helps in reducing
sample line deposits.

Plastic pipe or tubing (PVC, ABS, or polyethylene) is preferred for sample

line plumbing due to its corrosion resistance, lack of residual demand,
and smooth surface finish, which resists deposits. Never use copper pipe
or tubing. Avoid the use of metal lines or fittings.

Sample plumbing pipe (or tubing) size is a function of the available

pressure at the sample point (or sample pump discharge) along with the
sample line length and flow velocity required.

2.3.5.1 Potable Water

Four characteristics typical of potable water are that, generally, it

is low in particulates, it is available at reasonably high pressure
>1 bar (>15 psi), its use should be minimized, and the wetside may be mounted
within 7.5m (25 feet) of the sample point. In such applications, the sample
may be run through 6mm (¼-inch) pipe or tubing and the bypass flow on
the Y-strainer may be shut. It should be opened only intermittently to flush
the strainer element and sample line. Then only approximately 500 ml/min
of the sample is required, which is the internal analyser sample requirement.
2.3.5.2 Wastewater

Frequently, wastewater is high in particulates and biological growth potential.

The sample is taken from open channel flow, with no pressure available
at the sample point. Additionally, the wetside must frequently be mounted
a significant distance from the sample point (inside and protected from
weather). Here, a sample pump is required and the Y-strainer bypass flow
valve should be open to allow continuous flushing of the strainer element.
A high flow, low pressure, open impeller type pump works well in this
environment. Typical systems use ½-inch pipe or tubing that bypasses
7.6l/m (2 US gpm) through the Y-strainer or 3/4-inch pipe that bypasses
19l/m (5 US gpm). This results in a flow velocity of about 1.2m/s (4 feet/s)
and a pressure drop of about 0.3 bar (4 psi) per 30m (100 ft) of sample line.

Wastewater will frequently exhibit high biological growth potential; therefore,

the sample line may need to be treated with a cleaning (biocidal) agent
(typically chlorine) to inhibit growth in the sample line. Biological growth
may clog fittings in the sample line or wetside and consume (process) chlorine

18 W3T331759 / WT.050.585.003.UE.IM.1014
 MICRO/2000® AND DEOX/2000® MODULE

residual during the sample transit time in the sample line. For sample line
dosing, the cleaning agent is periodically injected into the sample line near
the sample intake point.

A self-flushing, 1/2-inch Y-strainer is provided and should be located at the

analyser. Valves are provided to be installed on the Y-strainer bypass discharge
to control bypass flow and at the filtered discharge from the Y-strainer to the
1/4-inch sample inlet at the base of the flow block.

The analyser enclosure is equipped with a hose adapter drain connection

for 1-1/4-inch hose.

a. Slip 1-1/4 inch drain hose over the end of the drain fitting and run
hose to a waste drain.

b. Connect a hose from the Y-strainer bypass valve to the waste drain.

c. Inside the wetside, insert the analyser bypass tubing and cell discharge
tubing (both 1/4-inch OD translucent) into the drain fitting.

1 Reducing Bushing, 1/4" x 1/2" NPT

2 1/4" x 1/4" Nipple
3 1/2" Nipple
4 90° Elbow
5 Nut-Union, 1/2-20 Thread
6 1/4" ID Tubing
7 Valve
8 Y-Strainer
9 1/4" T x T Labcock Valve
10 1/2" Single Entry Ball Valve

Figure 2.5 MICRO/2000® and DEOX/2000® sample line

2.3.6 Connect the device to the power supply

WARNING: Only authorized and qualified electricians are permitted to

install the device and open the housing. The device may only be taken
into operation when the housing is closed, and must be connected to
protection earth. Modifications to the device which go beyond those
described in this manual are not permissible.

W3T331759 / WT.050.585.003.UE.IM.1014 19
 MICRO/2000® AND DEOX/2000® MODULE

WARNING: The device is not equipped with a mains switch and is in

operation as soon as the supply voltage is applied. When connecting
system components (e.g. devices, motors, pumps), the system components
must be switched off.

CAUTION: To ensure safe and correct commissioning, knowledge of the

operation, connected electrical load, measurement signals, cable assignment
and fuse protection of the connected devices and machines and the relevant
safety regulations is required. The device may only be commissioned by
qualified and authorized electricians. Incorrectly connected devices can
be damaged, possibly irreparably, or cause faults in other equipment when
they are switched on or in operation. Ensure that the measuring and control
cables are not confused or make contact with one another. Never connect
or disconnect any cables to which voltage is applied.

NOTE: Refer to manual W3T168777 for SFC fusing details and manual
W3T159207 for the MFC fusing details.

2.3.7 Mounting the housing covers

1. Carefully place the housing cover onto the flow block assembly
and drop into place.
2.4 System Shut Down

CAUTION: Danger of uncontrolled dosing of chlorine or pH correction

medium: Shut down dosing system, close positioner!

NOTE: If the installation site of the flow block assembly is not frost
free, the system must be shut down prior to any possible frost formation.

1. Switch off the power supply.

2. Drain the sample water supply line and drainage line (hold container
underneath).

3. Empty cell bodies and remove grit.

4. Dismantle the filter housing and/or check valve housing.

5. When the remaining water has drained from the flow control valve,
refit the filter housing and the check valve housing.

6. Remove the sensors from the cell body cover and disconnect from
the cable.

20 W3T331759 / WT.050.585.003.UE.IM.1014
 MICRO/2000® AND DEOX/2000® MODULE

TOP HAT RAIL ASSEMBLY - DIMENSIONS

MICRO/2000® and DEOX/2000® Flow Block
50.590.100.050
ISSUE 1 7-14

W3T331759 / WT.050.585.003.UE.IM.1014 21
 MICRO/2000® AND DEOX/2000® MODULE

WALLMOUNT ASSEMBLY - DIMENSIONS

MICRO/2000® and DEOX/2000® Flow Block
50.590.100.060
ISSUE 1 7-14

22 W3T331759 / WT.050.585.003.UE.IM.1014
 MICRO/2000® AND DEOX/2000® MODULE

IC-Board (Mother board)

MICRO/2000 SFC Alarm 1
DEOX/2000 Power
4
WET SIDE
L2/N L1

20 21 22

Cable supplied E Green

PE L2/N L1

Power
L1/N 100...125VAC
L1/L2 220...240VAC
prefuse max.
100...240VAC 16A
power consumption. 15W
1) Shield earthed at one end

Temp Digital-In Feedback signal Analog-in

Ym
100%
0%

DI1 DI2
S

3 4 1 2 8 9 5 6 7 10 11 12

1)

0% 100% 1) 1)

- + + - - +
control stop 0/4...20mA 0/4...20mA 0/4...20mA
control constant 0...1V mA-input 1 mA-input 2
mA constant flow rate external setpoint/
single feed forward/ dosing factor
single feed back
External voltage must
not be connected
to the digital inputs!

SFC - SCHEMATIC WIRING

50.585.155.050A
ISSUE 1 1-11

W3T331759 / WT.050.585.003.UE.IM.1014 23
 MICRO/2000® AND DEOX/2000® MODULE

Relay Outputs - MICRO/2000 - DEOX/2000

Wet Side Power Connection

Power
L

24 23 22 21 20 19

N
Supply
1 2
E
1 2 E
E

Power
Cable Power
Fitted L1/N 100...125 VAC
L1/L2 220...240 VAC
MICRO-DEOX/2000

prefuse max:
WETSIDE 1

230/115V AC 6A

Sensor Module 1
Power
Cable
Fitted
See Drg 50.585.155.050F
MICRO-DEOX/2000
WETSIDE 2

Sensor Module 2

MFC - SCHEMATIC WIRING

50.585.155.050B
ISSUE 1 1-11

24 W3T331759 / WT.050.585.003.UE.IM.1014
 MICRO/2000® AND DEOX/2000® MODULE

3 pot cells Main

+temp. sensor Board
WRK

CNT
REF

Pt1000
1 2 3 4 5 6 7 8 3 4
shield

GRN
BRN
WH

RD
BK

MICRO/2000®
DEOX/2000®

1) Shield earthed at one end

SFC Sensor/Module Connection for CE Version

50.585.155.050F
ISSUE 0 9-10

W3T331759 / WT.050.585.003.UE.IM.1014 25
 MICRO/2000® AND DEOX/2000® MODULE

26 W3T331759 / WT.050.585.003.UE.IM.1014
 MICRO/2000® AND DEOX/2000® MODULE

3 SETUP AND CONTROL FUNCTIONS

List of Contents

Section
General Information 3.1
Overall function 3.1.1
MICRO/2000® and DEOX/2000®
flow block assembly 3.1.2
Measurement Inputs 3.2
MICRO/2000® and DEOX/2000®
flow block assembly 3.2.1
Temperature measurement 3.2.2

3.1 General Information

The SFC and MFC are measuring and control devices for use on potable
water, industrial process water and waste water.

Typical applications:

• Measurement and monitoring of water parameters

• Chlorine single feedback closed-loop control

Possible process measurements are:

• free chlorine
• total chlorine
• chlorine dioxide
• potassium permanganate
• sulphur dioxide
• sodium bisulphite

As an option, two additional control signal inputs can be installed to

log flow rate and external setpoint using combi-control or ratio control.

The integrated graphic display shows the following:

• Measured values
• Mode
• Bar graph with limit values
• Setpoint and measuring range
• Description of customized measuring points
• etc.

W3T331759 / WT.050.585.003.UE.IM.1014 27
 MICRO/2000® AND DEOX/2000® MODULE

The menus are easy to use, displayed in plain text and are selected using
softkeys.

3.1.1 Overall function

Possible measured values:

• Free chlorine*, total chlorine*, potassium permanganate*, chlorine

dioxide* ozone* (MICRO/2000® 3-electrode cell)
• Total chlorine*, sulphur dioxide* (DEOX/2000® 3-electrode cells)

* These measurements are automatically temperature-compensated.

The graphic display shows the measured data, limit values and setpoints
as numeric values, diagrams or a trend line.

3.1.2 MICRO/2000® and DEOX/2000® flow block assembly

These flow block assemblies guarantee a stable measurement signal with:

• Robust sensors
• Constant flow rate with the aid of the flow control valve
• Hydrodynamic grit cleaning of the Depolox® 5, MICRO/2000®
and DEOX/2000® flow block electrodes
• Optimum flow around all sensors
3.2 Measurement Inputs

In principle, the following sensor measuring module types or retrofit kits

can be installed at the module slot. The sensor measuring modules are
only supported in applications 1 and 2:

DES - for MICRO/2000® analyser with PT1000

DES - for DEOX/2000® analyser with PT1000

When the device is switched on, the menus are initialized according to
the installed sensor module. If the sensor modules are changed at a later
date, the user menus are automatically initialized when the device is
switched on. If no sensor measuring module is installed when the unit
Version 1, the message "No measurement available" appears.

The sensor measuring module should be considered as the main

measurement, and control functions such as ratio control, single feedback
closed loop, and combi-control are supported depending on the Process
Control option. No controller output is available for application 1.

28 W3T331759 / WT.050.585.003.UE.IM.1014
 MICRO/2000® AND DEOX/2000® MODULE

3.2.1 MICRO/2000® and DEOX/2000® flow block assembly

MICRO/2000® and DEOX/2000® Flow Block Assembly - 3

Electrode Measurement for Total and Free Cl2, ClO2, O3, or KMnO4
(MICRO/2000®), Total Cl2 and SO2 or NaHSO3 (DEOX/2000®).

A sensor module (“DES” for 3 electrode cells) and terminal strips are used
to connect the MICRO/2000® and DEOX/2000® flow block assembly
to the SFC. Various controller function are available depending on the
application selected.

3.2.1.1 MICRO/2000® flow block theory of operation

The measurement of free chlorine is made directly at a buffered pH of 4

with pH 4 buffer. The measurement of total chlorine is made by reacting
the various chlorine species with potassium iodide at the buffered pH, then
measuring the resulting iodine concentration.

The net reaction of chlorine with iodide is:

Cl2 + H2O-> 2H+ + OCl- + Cl- (hydrolysis of chlorine)

OCl- + 2I- + 2H+ -> H2O + Cl- + I2

The analyser measuring process is as follows:

A continuous sample is delivered to the analyser. A flushing Y-strainer

divides the sample into two streams—the larger bypass stream continuously
flushes the Y-strainer and the smaller stream, about 500 ml/min, flows
into the analyser. Most of the flow into the analyser is again bypassed,
but a small portion (15 ml) is metered from this flow by a peristaltic
metering pump. The reagents, pH 4 buffer for the measurement of free
chlorine residual and potassium iodide solution for the measurement of
total chlorine residual, are also metered by the same pump. The reagents
are then mixed with the sample as the sample is pumped to the analyser
cell. A three-electrode amperometric “probe” is immersed in the sample
in the cell. A rotating impeller stirs the sample and maintains a constant
sample velocity across the electrode surfaces. It also agitates the grit
used to clean deposits from the electrodes, improving the stability of
calibration. The amperometric cell produces a signal (electrical current)
proportional to the oxidant (e.g., chlorine) concentration in the cell.

29 W3T331759 / WT.050.585.003.UE.IM.1014
 MICRO/2000® AND DEOX/2000® MODULE

3 Electrode Cell

Impeller

Peristaltic
Pump

Internal Bypass

Calibration
3-Way Sample Flow Control
Valve Valve

Flushing
Y-Strainer
Drain
Chamber
Buffer Potassium Shut Off to Waste
Reservoir Iodide Reservoir Valve
5 litre 5 litre Relief Valve Set at 2 bar (30 PSI)
(1 Gallon US) (1 Gallon US)
Priming
(Total Residual) Port
4-19 l/m
(1-5 Manual
US GPM) Bypass Valve
Water Sample

Sample Pump
(For wastewater applications)
Sample Line
Dosing
(If Used)

Figure 3.1 Flow Diagram

3.2.1.2 DEOX/2000® flow block theory of operation

The DEOX/2000® Analyser gives a continuous on-line determination of

SO2 residuals by metering a predetermined amount of Potassium Iodate,
along with pH4 buffer and potassium iodide, into a metered quantity of
process water sample. This constant level addition of iodine is termed
the “Iodine Bias”. The DEOX/2000® analyser detects this iodine level
as a proportional electric current (µA) in the same manner it does with
chlorine. Once in operation, change in current indicates the presence of a
chlorine or SO2 residual in the process water—depending on whether the
change is an increase or decrease in iodine concentration, respectively.
Iodine reacts with SO2 in the same manner that chlorine reacts with SO2,
therefore, the amount of iodine consumed represents the amount of SO2
residual in the water. Conversely, if there is an increase in the iodine
concentration (above the bias concentration), a chlorine residual is
indicated and can be accurately determined.

W3T331759 / WT.050.585.003.UE.IM.1014 30
 MICRO/2000® AND DEOX/2000® MODULE

Iodine is used as the “biasing reagent” because it is less likely (and

slower to react with organic oxidant demand, making determination of
residuals more reliable than a hypochlorite (chlorine) biased measurement.
Because iodine is not stable in solution (i.e., is volatized and reacts
readily), Potassium iodate solution is reacted with potassium iodide (KI)
and releases iodine as used. This conversion reaction takes place in the
long length of “reaction” tubing where the mixed reagents react before
entering the water sample.

The analyser measuring process is as follows:

A continuous sample is delivered to the analyser. A flushing Y-strainer

divides the sample into two streams—the larger bypass stream
continuously flushes the Y-strainer strainer element and the smaller
stream, about 500 ml/min, flows into the analyser. Most of the flow into
the analyser is again bypassed, but a small portion is metered from this
flow by a peristaltic metering pump. The reagents, Potassium Iodate in
pH4 buffer and potassium iodide in distilled water, are also metered by
the same pump. As the reagents are discharged from the pump, they are
combined and reacted in a length of tubing referred to as the reaction
tubing. The reacted reagents are then mixed with the sample inlet to the
metering pump and the “Biased” sample then enters the analyser cell. A
three- electrode “probe” is immersed in the sample in the cell. A rotating
impeller stirs the sample and maintains a constant sample velocity across
the electrode surfaces. It also agitates the grit used to clean deposits from
the electrodes, improving the stability of calibration. The three-electrode
amperometric cell produces a signal (electrical current) proportional to
the oxidant (iodine) concentration in the cell.

3.2.1.3 Sample flow adjustment

Before starting the sample pump or otherwise starting sample flow, check that
the bypass control valve on the bypass leg of the Y-strainer, at the analyser, is
open and that the sample flow control valve to the inlet of the analyser is closed.

CAUTION: To prevent possible equipment damage, apply up to a maximum

of 0.3 bar (5 psi) water pressure to the analyser sample input. The tubing
in the analyser metering pump cannot withstand more than 5 psi pressure.
If pressure in excess of 0.3 bar (5 psi) is applied to the analyser input, fluid
may be sprayed from the analyser metering pump inlet.

CAUTION: Pressures in Excess of 0.3 bar (5 psi) will cause the the
tubing passing through the peristaltic pump to expand resulting in an
increase in flow and hence a change in the dilution ratio. Ideally the flow
to the drain should not be any more than a constant drip.

31 W3T331759 / WT.050.585.003.UE.IM.1014
 MICRO/2000® AND DEOX/2000® MODULE

3.2.1.4 Probe installation

The probe should be installed in the analyser after the rest of the analyser
installation (mounting, plumbing, wiring) is completed and inspected.

CAUTION: Do not fill the probe with electrolyte until immediately before
it is installed in the analyser. Once the probe is filled with electrolyte, the
electrode end must be kept wetted, as it is when installed in the analyser. If
the probe is filled and the porous element is allowed to dry, the pores will
clog with potassium chloride crystals.

Fill the probe (through the fill hole in the side of the probe body) with
electrolyte. Fill only to a level just below the fill hole when the probe is
upright. The hole plug is not watertight.

Remove the protective cap from the electrode end of the probe. Check
that the electrodes are clean; wipe clean with a paper towel if necessary.
Do not touch the electrodes (platinum elements) or the porous element
(white element), as finger dirt or oil may impede the probe operation.
The platinum material is thin and easily punctured or sheared off. The
electrodes are not repairable.

Allow the probe to stand upright (or hang it by its cord) for about
ten minutes until electrolyte emerges from the porous element. If the
electrolyte does not emerge shortly, it can be forced through the porous
element by pressurizing the reservoir with a rubber squeeze bulb - used
to force air into the fill hole. Use a sharp blade or a pointed object to cut
a small vent hole in filling hole plug, enough to allow air through and
equalize to atmospheric pressure on both sides of the plug. Replace the
hole plug to prevent evaporation of the electrolyte.

Connect cable to input module.

3.2.2 Temperature measurement

The IC board of SFC has a temperature measurement for connecting a

PT 1000 sensor (multi-sensor). This temperature measurement is used for
temperature compensation of the "DES" module and pH measurement. The
temperature is shown on the main display and can be calibrated if necessary.
The measuring range is 0 – 50 °C. The unit may be adjusted to °F.

32 W3T331759 / WT.050.585.003.UE.IM.1014
 MICRO/2000® AND DEOX/2000® MODULE

4 OPERATION

List of Contents

Section
Display and Operator Controls 4.1
Operator controls 4.1.1
Notes On Operation 4.2
Operation 4.2.1
Menu Structure 4.3
Calibration 4.4
Temperature Calibration 4.4.1
MICRO/2000® & DEOX/2000® Calibration 4.4.2
Errors 4.5

4.1 Display and Operator Controls

Graphic display and operating panel

All information is shown on the graphic display.

Analyser 1 DI
I
DI
II 12:20

0,15 mg/l
Cl2 free
Tank
Wq =
1000l/s
75% 22,0°C
MENU CAL MODE

Figure 4.1 - Graphic display

The SFC is operated with nine keys. The software function is controlled
with the top three keys (softkeys).

s s s

s
s

ESC 3

Figure 4.2 - Operating panel

W3T331759 / WT.050.585.003.UE.IM.1014 33
 MICRO/2000® AND DEOX/2000® MODULE

The exact depiction of the individual parameters on the graphic display

is described in section 4.3, Menu Structure.

4.1.1 Operator controls

Softkey
• Activate the function shown on the graphic
display with the keys.
Up
• Move up one level.
• Display the previous option.
• Increase the value.
Down
• Move down one level.
• Display the next option.
• Decrease the value.
Left/right
• Change the column in the menu.
• Change the position in the displayed value (cursor menu).
• Move forwards or backwards by six hours in the trend graph.
Escape
ESC • Cancel the entry without saving the new value.
• Move up one menu level.
Enter/Acknowledge
• Acknowledge alarm message.
3 • Set the running delays to zero.
• Delete adaption error.
• Acknowledge max. dosing time to reactivate dosing.
4.2 Notes On Operation

During operation observe the following points:

• Check your entry and modifications before exiting the menu.

• Only press the keys with your fingers, never with hard or pointed
objects such as pencils, etc. This could damage the sealed keypad.

4.2.1 Operation

You have the following options starting from the basic display (the basic
display is opened by pressing the "ESC" key in the menu four times):

34 W3T331759 / WT.050.585.003.UE.IM.1014
 MICRO/2000® AND DEOX/2000® MODULE

Switch between the basic • Press the up or down key

displays and trend graphs
Select menu • Press the “MENU” softkey to select the
menu
• Press the “CAL” softkey to calibrate
• Press the “MODE” softkey to set the
operating mode
Select a menu item in the • Select the menu item with the arrow
menu display keys (arrow in front of menu item)
• Confirm the selection with “ENTER”
Change/enter displayed • Select the parameter with the arrow
parameters keys (arrow in front of parameter)
• Confirm the selection with “ENTER”
• Change/enter the display with the up or
down arrow keys
• Confirm the entry with “ENTER”
Cancel entry • Press the “ESC” key to exit the menu
item.
Entries which have not been confirmed
are reset to their original settings.
Reactivate password This function is only active when a
protection password has been programmed.
• Change/enter displayed parameters
• Block the system entry with the “LOCK”
softkey in the menu display

Exit the menu item • Press the “ESC” key

or
• Press the “BACK” softkey

4.3 Menu Structure

The SFC and MFC have various menus:

• Main menu
• Module type, e.g. Cl2 free 1
• Inputs/Outputs
• Alarms
• System
• Diagnosis
• Calibration
• Mode

Display of these depend on the number of sensor measuring modules

installed.

NOTE: For full menu details refer to manual W3T168777 for SFC and
manual W3T159207 for the MFC.

W3T331759 / WT.050.585.003.UE.IM.1014 35
 MICRO/2000® AND DEOX/2000® MODULE

The “Calibration” and “Mode” menus are opened with the corresponding
soft keys directly from the basic display. All other menus can be accessed
with the “MENU” softkey.

4.4 Calibration

CAUTION: The electrode fingers or membranes on the sensors are

extremely sensitive. Do not touch, soil or damage them.

NOTE: To prevent loss of control during calibration, the “Hold function” in

the system/common menu should be set to “On” (mA-outputs and
controller outputs then remain constant during calibration). To determine
how often you must calibrate, refer to section 5.1, Maintenance Schedules.

4.4.1 Temperature calibration

1. Starting from the basic display in the main menu select the
“Calibration” menu.

2. Select the “Temperature” menu item The “Calib. temperature”

window appears on the graphic display.

3. Select “Cal. temperature”.

4. Perform comparative temperature measurement

5. Open the menu with the “Enter” key and enter the ascertained value
with the arrow keys.

6. Save the value by pressing the "Enter" key.

NOTE: °C or °F can be selected in the “Temp. unit” menu. The required

temperature input can be selected or switched off in the "Temp. sensor" menu.

4.4.2 MICRO/2000® calibration

Before beginning calibration, choose the method of calibration (1 point

or 2 point).

4.4.2.1 One point calibration:

Grab Sample Method

1. Select the 1 Point calibration method in the calibration menu.

2. Once the reading on the system is stable, collect a sample from the
water line.

3. Measure the residual contained in this sample.

4. Enter this value as the “SPAN” value.

36 W3T331759 / WT.050.585.003.UE.IM.1014
 MICRO/2000® AND DEOX/2000® MODULE

Standard Solution Method

1. Select the 1 Point calibration method in the calibration menu.

2. Create a 500 ml sample solution of a desired concentration within

the intended operating range.

3. Allow the sample solution to pump through the sample line for
aminimum of 10 minutes using the 3-way inlet valve (see Figure 4.3).

4. When the display stabilizes, enter the solution concentration (mg/l)

as the “SPAN” value.

4.4.2.2 Two point calibration:

1. Select the 2 Point method of calibration in the calibration menu.

2. Obtain 500 ml of demand free water.

3. Allow the demand free water to pump through the sample line for a
minimum of 10 minutes using the 3-way inlet valve (see Figure 4.3).

4. Once the reading is stable, enter this value as “ZERO”.

5. Complete “Grab Sample Method” above for “SPAN” calibration.

This concludes the MICRO/2000® calibration.

4.4.2.3 Calibration tips

Because the analyser is on-line, the process should be observed for a few
moments before and while taking the sample to ensure that the process
does not deviate suddenly during sample taking and before initiating the
calibration. A substantial change in the process during calibration results
in an inaccurate calibration.
FROM
PROCESS FLOW TO TO
SAMPLE METERING METERING
STREAM PUMP PUMP

FLOW

FROM
CALIBRATION
SAMPLE

TO RUN TO CALIBRATE
Figure 4.3
Figure 4.3

W3T331759 / WT.050.585.003.UE.IM.1014 37
 MICRO/2000® AND DEOX/2000® MODULE

4.4.2.4 DEOX/2000® BIAS calibration

In performing the BIAS calibration, the slope is calibrated by directly measuring

the residual “bias” resulting from the reagents (iodine) added to the cell. This
bias can be directly determined only by operating the analyser on zero residual,
chlorine demand free water (distilled water), so that the iodine bias residual is
the only source of residual. The full procedure is discussed below.

CAUTION: For the BIAS calibration to be accurate the sample water and
the distilled water should be at the same temperature.

A full slope calibration of the analyser is generally preformed upon start-up

and periodically thereafter.

The nominal Bias value is 1½ times the range of the analyser. Due to
variations in feed rate, the actual Bias can vary ± 25%.

a. Place 500 ml of demand free water in a 500 ml flask, and place the
flask in the wet side on top of the flow cell. This will cause a small
pressure (head) a flooded suction. A 500 ml beaker will not fit.

b. Attach two feet of 1/8-inch ID flexible tubing to the calibration leg

(middle leg) of the calibration valve. Put the end of the calibration
leg (middle leg) tubing of the calibration valve into the flask.

c. Move to the BIAS calibration function in the calibration menu of

the user interface.

d. Move the calibration valve lever to the calibrate position. This

closes the valve inlet from the process sample and opens the inlet
to the contained sample.

FROM
PROCESS FLOW TO TO
SAMPLE METERING METERING
STREAM PUMP PUMP

FLOW

FROM
CALIBRATION
SAMPLE

TO RUN TO CALIBRATE
Figure 4.4
Figure 4.4

38 W3T331759 / WT.050.585.003.UE.IM.1014
 MICRO/2000® AND DEOX/2000® MODULE

e. The pump is now drawing sample from the beaker. Allow the
sample to purge the pump and cell for five minutes. Wait for the
measured concentration to stabilize. Watch the water level in the
flask during this period and refill as required. Do not allow the
pump to suck in air, as this disrupts the calibration. If this occurs,
get out of the calibration procedure and wait for the analyser to
stablize (10-minute delay) before reattempting calibration.

f. The screen will display the “BIAS” and “Temp Calibration” on the
left and the current bias value and microamp (μA) cell signal on the
right. Press the down arrow to access the “Temp Calibration” menu.
The cell signal value will be replaced by the current temperature
value. If necessary, enter the “Temp Calibration” menu and calibrate
the temperature as required.

g. Return to the “BIAS” calibration menu. Monitor the microamp cell

signal until it stablilizes. The signal will vary by ± 5%, but will
stabilize around a middle point.

NOTE: The microamp cell signal is dependant on the operating range

of the unit, with higher range units having a higher signal strength.Once
the signal is stable, enter the desired bias value (1½ x range). Return to
main display and allow unit to operate on demand free water. Displayed
residual should be zero (± 5%). Adjust bias as required for zero residual.

h. If the calibration is completed before the 10-minute delayed return

to operation, the mA is still frozen. The main display continues to
function, with a message indicating the delay is in effect.

4.4.2.5 Calibration Tips

The bias calibration method requires that the sample be taken from the
cell discharge, where the BIAS produced by the reagents can be directly
measured. This sample flow is approximately 16 ml/min. The amperometric
titration measurement method requires a 200 ml sample, which requires
a sample time of from 12 to 30 minutes. Because of the unstable nature
of the iodine residual, particularly in a reactive process, it is not good
practice to wait this long to take the sample. If direct measurement of
the sample cell residual is desired, it can be done as follows:

1 Take a sample of exactly 200 ml (e.g., use a volumetric pipette).

2 Dilute it to 200 ml with distilled water in the titration cup. Titrate

with 10:1 PAO solution (or, if standard strength PAO is used,
multiply the titration value by 10).

W3T331759 / WT.050.585.003.UE.IM.1014 39
 MICRO/2000® AND DEOX/2000® MODULE

4.5 Errors and Remedies

Error Messages

The following table shows and explains all possible error messages
which can be displayed. If several errors occur at the same time, the
corresponding messages appear alternately in succession. When the error
has been remedied, the error message is automatically deleted.

If you are unable to remedy the error yourself, please contact your local
Evoqua Water Technologies service department.

Table 4.1 - Error Message

Error message Cause Remedy
Measured value Measured value is Check measuring range and
display flashes outside the measuring change, if necessary.
range
Check dosing or controller
settings
Zero ? In 3 electrode cells Electrodes in the 3 electrode
Sensor has zero current cell are soiled; clean and
> +5 μA or < -5 μA service, if necessary

Sample water is turned off or

sample line leaks

Upot potential voltage set

incorrectly; change, if necessary
Calibration ? In 3 electrode cells Check whether there are air
Slope error - the sensor bubbles on the membrane
current based on 1 mg/l sensor and remove, if
has fallen below the necessary
required minimum In Service membrane sensors
measuring range: - replace electrolyte/
In measuring range: membrane cap
10 μA: in. 0.04 μA/mg/l Clean 3 electrode cells,
70 μA: in. 0.2 μA/mg/l replace cell sand
100 μA:min. 0.4 μA/mg/l
200 μA: min. 2 μA/mg/l
1000 μA: min. 4 μA/mg/l
Temperature? Interruption in the Check multi-sensor and cable
temperature
sensor or cable
Temp. mod? Temperature Check the temperature
measurement sensor and cable
of the sensor
measurement
module is faulty
Interruption in the
temperature
sensor or cable

40 W3T331759 / WT.050.585.003.UE.IM.1014
 MICRO/2000® AND DEOX/2000® MODULE

Cell ? In 3 electrode cells: Connect sensor correctly.

Chlorine sensor not Check sand cleaning; add if
connected properly necessary
No sand cleaning Check the sensor, sensor
Sensor, sensor cable or cable or sensor module,
sensor module defective replace if necessary
Sensor measuring Select higher μA measuring
module μA measuring range
range exceeded
Range? Min/max limit value is Check the min/max limit
outside values and change, if
the measuring range necessary
Sample Line Dos Automatic sample water Time-controlled function is
inlet disinfection ended automatically, as soon
as the process is complete

Error

The following table shows and explains possible errors which can occur.
If you are unable to remedy the error yourself, please contact the Evoqua
Water Technologies service department.

Table 4.2 - Errors

Error Cause Remedy
No indication on No power supply External switch or fuse off
device Device fuse defective Check the power supply and
replace fuse
Housing cover is fitted Check, fit the housing cover
incorrectly (MFC units correctly (cable possibly
only) trapped)
Measured value Measuring module Check, refit module correctly,
display not defective or fitted replace measuring module
available, although incorrectly
the appropriate
measuring
module is installed

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42 W3T331759 / WT.050.585.003.UE.IM.1014
 MICRO/2000® AND DEOX/2000® MODULE

5 MAINTENANCE

List of Contents

Section
Maintenance Schedules 5.1
Check for tightness 5.1.1
Check the cell sand 5.1.2
Maintaining MICRO/2000® and
DEOX/2000® Flow Block Assembly 5.2
Wetside panel removal and replacement 5.2.1
Occlusion ring removal and replacement 5.2.2
Pump, rotor, rollers and thrust washer
Removal and replacement 5.2.3
Pump tubing units replacement 5.2.4
Pump bearing replacement 5.2.5
Impeller shaft seal replacement 5.2.6
Impeller motor removal and replacement 5.2.7
Impeller shaft replacement 5.2.8
Pump motor removal and replacement 5.2.9
Probe electrolyte and electrodes 5.2.10
Probe cleaning, refilling and porous
element replacement 5.2.11

5.1 Maintenance Schedules

The following maintenance schedules are recommendations only. Adhere

to the appropriate standards, regulations and locally applicable guidelines.

Task Period/Interval
MICRO/2000® and DEOX/2000® flow block assembly
Check for leakages Weekly
Comparative measurement, calibrate if
Weekly/acc. to guidelines
necessary
Check electrolyte level (MICRO/2000® and
Weekly
DEOX/2000®)
Check cell sand (MICRO/2000® and
Weekly
DEOX/2000®)
Change cell sand (MICRO/2000® and
Every six months
DEOX/2000®)
Change electrolyte (MICRO/2000® and
Every six months
DEOX/2000®)
Change porous element (MICRO/2000® Every six months (depending
and DEOX/2000®) on water quality)
Replace the impeller shaft and shaft seal Yearly

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 MICRO/2000® AND DEOX/2000® MODULE

5.1.1 Check for tightness

Check the entire measuring device including all screw connections for
leakage. Repair any leakage points immediately.

NOTE: Air bubbles in the sample water influence the measuring accuracy.
The cause must be determined and remedied.

5.1.2 Checking the cell sand

Check that there is sufficient sand in the cell body. The cell sand must
be swirled around in the bottom section of the cell body. The cell sand
is necessary for cleaning the chlorine sensor electrodes and must be
replenished or replaced when required. (Refer to section 2.3.2 "Pour in the
cell sand (only with MICRO/2000® and DEOX/2000®)" and "Changing
cell sand with 3-electrode cell MICRO/2000® and DEOX/2000®".)

NOTE: When fresh sand is replenished, the electrode current may increase
slightly for approximately 3 hours. Do not calibrate during this time. You
must calibrate each time the cell sand is replaced. The calibration must
be checked after one day.

5.2 Maintaining MICRO/2000® and DEOX/2000® Flow Block Assembly

WARNING: To avoid electrical shock, turn off power before servicing.

WARNING: To avoid electrical shock or damage to equipment, avoid

contact with circuit board components while making adjustments.

WARNING: Wear recommended protective eyewear when servicing

the wet components of the analyser, particularly when servicing reagents
and reagent lines. The analyser uses chemicals that can cause severe
personal injury by chemical burns on contact with eyes. Rinse any area
of contact immediately. If chemicals contact eyes, rinse from eyes and
seek immediate medical attention.

5.2.1 Wetside panel removal and replacement

1. Shut off sample flow to the analyser.

2. Disconnect the probe and motor connectors from the SFC electronics,
if those parts will be serviced.

3. Remove the probe and set it carefully aside. Do not rest it on its
electrode end. If the probe will be removed for more than an hour,
place it, with the electrodes, in a beaker of water.

44 W3T331759 / WT.050.585.003.UE.IM.1014
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4. Disconnect the liquid reagent tubing from the inlet and discharge
of the metering pump.

5. Disconnect the water sample tube from the panel inlet.

6. Disconnect the drain tubing from drip tray outlet.

7. Remove the clamps holding the probe cable, if probe will be

serviced.

8. Remove the four screws holding the panel in the enclosure, and
remove the panel from the enclosure. The panel will hang in front
of the enclosure on strain relief cables.

9. Hold the panel upright while removing it to avoid spilling water

trapped in the cell. Remove mounting screws and set aside before
releasing panel. There is water trapped in the various tubing units
and chemical trapped in the reagent tube units.

5.2.2 Occlusion ring removal and replacement

WARNING: To avoid possible severe personal injury or equipment

damage, observe the following:

Turn off the flow to the analyser before removing the occlusion ring from the
metering pump. The occlusion ring stops the free flow of liquid through the
analyser sample lines. If it is removed with flow still present at the analyser,
process water will be sprayed from the pump discharge line and from the
cell top. Sprayed process water can create an electrical shock hazard due to
the presence of dangerous voltage powering the impeller and pump motors.

Do not service the metering pump while it is turning, the metering pump has
enough torque to cause severe personal injury if hands are pinched in the
rotating parts. Disconnect the pump motor POWER before servicing the pump.

Wear recommended protective eyewear when servicing the wet components

of the analyser, particularly when servicing reagents and reagent lines. The
analyser uses chemicals that can cause severe personal injury by chemical
burns on contact with eyes. Rinse any area of contact immediately. If chemicals
contact eyes, rinse from eyes and seek immediate medical attention.

5.2.2.1 Removal

a. Disconnect power to the wetside of the analyser by disconnecting

the power supply from the SFC electronics.

W3T331759 / WT.050.585.003.UE.IM.1014 45
 MICRO/2000® AND DEOX/2000® MODULE

b. Turn off the water supply to the analyser.

c. Remove the wetside panel (optional). See paragraph 5.2.1, Wetside

Panel Removal and Replacement.

d. Using a 7/16-inch socket wrench, remove the two bolts (with

washers) attaching the occlusion ring to the panel. Lift off the
occlusion ring. Some residue from the tube units accumulates on
the ring during usage. This is normal.

5.2.2.2 Replacement

The occlusion ring may be difficult to reinstall if the following procedure is

not followed. Do not use excessive force. Use care not to pinch the tube units
(installed on the pump rollers) when installing the occlusion ring. Before
reinstalling the occlusion ring, check that the pump tube units are properly
seated in the roller grooves and in the tube retainer grooves. See paragraph
5.2.4, Pump Tubing Units Replacement.

1. Place the occlusion ring loosely in place over the tube units, but
do not attempt to clamp the occlusion ring in place yet.

2. Hold the ring in place with one hand and slide a bolt, with washer, into
the lower mounting hole in the ring until it bottoms against the casting.

3. Gently squeeze the ring against the tubing while pushing the bolt
into place. The bolt will drop (about ¼ inch) into place when the
ring is properly located.

4. Tighten this first bolt a few turns, so that the occlusion ring will
pivot on the bolt.

5. Slide the second bolt (and washer) into its mounting hole in the ring.

6. Firmly squeeze the ring against the pump rotor (squeeze near the
second bolt) to obtain leverage against the pivot bolt until the
second bolt drops into place. Finger tighten bolts until occlusion
ring is flat against panel.

7. Tighten bottom bolt 1/4 turn, then tighten top bolt 1/4 turn.

5.2.3 Pump rotor, rollers and thrust washer removal and replacement

The rotor is fastened to the motor shaft by a set screw requiring a 3/32-inch
Allen wrench for adjustment.

46 W3T331759 / WT.050.585.003.UE.IM.1014
 MICRO/2000® AND DEOX/2000® MODULE

When the rotor body is removed, check the rollers, roller shafts, thrust washer,
the shaft bearing, and shaft bore in the rotor body for signs of excessive
wear, damage, or corrosion. Some residue on the roller shafts and inside
the rollers is normal. The rotors should function properly for at least one
to two years. Do not lubricate the rollers, as some greases may attack the
nylon roller material. Lubrication of the rollers is not necessary. If any of
the roller shafts show significant wear marks and the corresponding roller
is loose, the rollers and rotor body unit must be replaced.

5.2.3.1 Removal

1. Remove the wetside panel from the enclosure, see section 5.2.1.

2. Remove the occlusion ring from the panel unit.

3. Remove the sample and reagent tube units from the metering pump.

4. Locate the set screw in the hub of the rotor body (just behind the
back face of the body) and loosen the set screw one or two turns.

NOTE: Hold the panel upright while removing the rotor body to avoid
dropping and losing the rollers. To use as a guide for reinstallation, take
note of the orientation of the rollers (small groove toward the front of
the panel) before removing the rotor.

5. Slide the rotor body off the motor shaft.

6. The thrust washer (located against the panel assembly) should be removed
and set aside so that it does not drop off the panel and become lost.

5.2.3.2 Reinstallation

1. If the thrust washer was removed, reinstall it over the pump hub,
against the panel.

2. Install the rollers on their shafts in the position noted during the
removal of the rotor (small groove toward front).

3. Look into the shaft bore in the rotor body and adjust the set screw
until it just protrudes into the bore (approximately a half turn). The
set screw protruding into the bore helps to locate it on the flat of
the shaft as the rotor assembly is installed.

4. Note the position of the flat on the pump shaft and slide the rotor
assembly onto the shaft with the set screw over the flat.

W3T331759 / WT.050.585.003.UE.IM.1014 47
 MICRO/2000® AND DEOX/2000® MODULE

5. The shaft bore has a sliding fit on the shaft, so there may be a slight
resistance to the sliding. If the resistance seems excessive, back-off
the set screw a quarter turn and twist the rotor body back and forth
slightly as it slides back onto the shaft.

6. Tighten the set screw gently, until it begins to lock in place, on the
flat on the shaft. Be sure that the hub of the rotor is flush against the
pump hub (but without pressure) when the set screw is tightened.
Using the Allen wrench, tighten the set screw as firmly as is
practical. Use pliers to apply additional torque, but not so much
as to permanently deform the Allen wrench.

NOTE: If the set screw is not tightened sufficiently, the rotor may wobble
on the shaft or may slip on the shaft, damaging the shaft and causing the
pump to not operate properly.

5.2.4 Pump tubing units replacement

WARNING: Turn off the flow to the analyser before removing the
occlusion ring from the metering pump. The occlusion ring stops the
free flow of liquid through the analyser sample lines. If it is removed
with flow still present at the analyser, process water will be sprayed from
the pump discharge line and from the cell top. Sprayed process water
can create an electrical shock hazard due to the presence of dangerous
voltage powering the impeller and pump motors.

Do not service the metering pump while it is turning, the metering pump
has sufficient torque to cause severe personal injury if hands are pinched
in the rotating parts. Disconnect the p ump motor connector before
servicing the pump.

Wear recommended protective eyewear when servicing the wet

components of the analyser, particularly when servicing reagents and
reagent lines. The analyser uses chemicals that can cause severe personal
injury by chemical burns on contact with eyes. Rinse any area of contact
immediately. If chemicals contact eyes, rinse from eyes and seek immediate
medical attention.

The sample and reagent tube units include glued stop rings and adapters
and fittings. Replace the entire unit when required.

The tube units should provide approximately six months of service, but
should be observed monthly (without disturbing the analyser) for signs
of wear or leakage. If either condition is noticed, replace the suspected
tube units immediately.

48 W3T331759 / WT.050.585.003.UE.IM.1014
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Remove the tube units only when replacement units are readily available, so
there is no confusion about how to reconnect the new tube units.

• Removal of the tube segments is as follows:

a. Disconnect power to the wetside.

b. Disconnect the sample and reagent tubing from the fittings at the ends
of the tubing segments. The fittings are replaced with the tube units.

c. Remove the occlusion ring mounting bolts (requires a 7/16-inch socket).

d. Remove the tube units.

• Installation of tube units (refer to Figure 5.1):

A Occlusion ring
B Sample tube
C Reagent tube
D Reagent groove
E Sample groove
F Retainer surface
G Sample segment - roller
H Reagent segment - roller
I Roller
J Tube retaining collar
K Tubing connector

Figure 5.1

1. Remove the occlusion ring (A).

2. Remove the old tube units (B or C) (if replacing).

3. Both reagent tube units (C) fit into the small groove (D) on the tube
retainer (F), as well as into the small groove (H) on the rollers (G).

W3T331759 / WT.050.585.003.UE.IM.1014 49
 MICRO/2000® AND DEOX/2000® MODULE

The sample tube unit (B) fits into the large groove (E) on the tube retainer
(F) and the large groove (I) on the rollers (G).

Guide the (new) tube unit through the small (D) or large (E) groove in the
lower end of the tube retainer (F) and slide the unit up through the groove
until the lower tube stop (J) is against the outer surface of the tube retainer (F).

4. Lay the tube unit (A or B) over the pump rollers (G) in the small (H)
or large (I) groove, toward the front of the pump rollers. If two reagent
tube units (C) are installed, ensure that the tubes lay side by side and
do not cross each other when placed over the rollers (G).

NOTE: If the pump is operated with the reagent tube units crossed, the
tube units may be damaged.

5. Stretch the tubing slightly and guide it through the small (D) or large
(E groove in the upper end of the tube retainer (F), with the upper tube
stop (K) above the top surface of the upper end of the tube retainer
(F). When tension on the tubing is released, the tube stops should be
against the outside surfaces of tube retainer.

6. Check that the tube units (B or C) are in their proper small (H) or large
(I) groove in the roller (G). Check that the reagent tubes do not cross.

7. Replace the occlusion ring, so that the larger inside radius (in which the
sample tubing (B) rides) is facing away from the operator. Locate and
start the lower mounting bolt before attempting to squeeze the occlusion
ring against the tubing. Then secure the second mounting bolt.

The tubing exerts side pressure on the retaining bolts, causing some tendency
for cross-threading of the bolts as they are reinstalled. Do not force the bolts.
If they do not turn smoothly, remove them and install them again.

5.2.5 Pump bearing replacement

1. Remove the wetside panel from the mounting enclosure.

2. Remove the pump occlusion ring, tube units, rotor body (with rollers),
and thrust washer from the front of the wetside panel.

3. Remove the pump motor from the rear of the wetside panel. The
pump mounting screws are on the face of the panel.

4. Drive the bearing out of the front of the casting using the square
end of a rod that is approximately ½-inch in diameter by 4 inches
long. (A socket wrench socket on an extension will work.) Use
care not to scar the bore in which the bearing is pressed.

50 W3T331759 / WT.050.585.003.UE.IM.1014
 MICRO/2000® AND DEOX/2000® MODULE

5. Tap in the new bearing until it is flush with the end of the bearing
support. Place the long side of a flat bladed screwdriver over the
bearing face and tap with a hammer. Make sure the new bearing
is square to the bearing support bore.

5.2.6 Impeller shaft seal replacement

5.2.6.1 Removal of the Impeller Shaft Seal

1. Disconnect power to the wetside of the analyser.

2. Remove the probe from the cell body. Make sure the probe electrodes
are not scratched or damaged. Lay the probe on its side so that the
electrodes do not contact any surface, but in a position so that the
electrolyte does not leak from reservoir fill hole.

3. Remove the cell body retaining screws and remove the cell body.
When removing the cell body take notice of the O-ring that seals
the cell body against the seal adapter. This O-ring may cling to the
cell body and then fall off.

4. Use a 3/32-inchAllen wrench to loosen the set screw holding the impeller
on the shaft. This set screw leaves a noticeable mark on the shaft. If the
shaft is not replaced, reinstall the impeller in the same position.

5. Slide the grit guard off the shaft.

6. Slide the seal adapter, with the seal and impeller shaft bearing,off
the shaft.

7. Using a pair of needle nose pliers, grab the center of the seal
andremove it from the front of the adapter.

8. Using a nut driver or small socket and extension, press the impeller
shaft bearing out of the seal adapter from the front.

9. Rinse the grit from the cell body, cell body sealing O-ring, impeller,
and seal adapter. Wipe the sealing surfaces and the shaft (gently)
with a paper towel to remove all grit and residue.

10. Check the shaft for signs of unusual wear, which indicates that it needs
replacement. Refer to Impeller Shaft Replacement instructions.

5.2.6.2 Installation of shaft seal

1. If not already done while removing old shaft seal, rinse grit from
the cell body, cell body sealing O-ring, impeller, and seal adapter.
Wipe the sealing surfaces and the shaft (gently) with a paper towel
to remove all grit and residue.

W3T331759 / WT.050.585.003.UE.IM.1014 51
 MICRO/2000® AND DEOX/2000® MODULE

2. Press new impeller shaft bearing into back of seal adapter. Apply a
small quantity of silicone grease to front and back bearing shaft hole.

3. Apply a small quantity of silicone grease to the back side (the

frontside is the concave side) of the new U-cup before installation
into the seal adapter.

4. Install the U-cup into the seal adapter, making sure the edges are
fully seated (flush with the inside diameter of the seal adapter).

5. Slide the seal adapter over the impeller shaft until it seats in the
panel. Wipe any excess grease from the front of the shaft.

6. Slide the grit guard (small end first) onto the shaft and up against
the seal adapter.

7. Slide the impeller onto the shaft, up to the grit guard. Retighten
the set screw until just snug.

8. Install the cell body sealing O-ring on the front of the seal adapter.

9. Install the cell body with the retaining screws and washers.

10. Replace the probe.

11. Restart the analyser.

12. Once the flow is restarted and the cell body is full of sample, replace
the grit.

5.2.7 Impeller motor removal and replacement

5.2.7.1 Removal

1. Remove the panel assembly from the mounting enclosure. See

paragraph 5.2.1, Wetside Panel Removal and Replacement.

2. Remove the cell body, impeller, and shaft seal adapter from the front
of the panel assembly. See paragraph 5.2.6, Impeller Shaft Seal
Replacement.

3. Turn the panel over and remove the ground lug screw and motor
mounting screws.

52 W3T331759 / WT.050.585.003.UE.IM.1014
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4. Remove the motor with the impeller shaft.

5. If the motor is being replaced, remove the impeller shaft and coupling
from the motor.

5.2.7.2 Replacement

Replacement is basically the reverse sequence of removal.

Grease the impeller shaft seal, with suitable silicone grease, before
reinstalling it on the front of the panel assembly.

WARNING: Always reconnect the grounding leads when removed or

broken. Grounding leads are provided for safety, to prevent injury from
electrical shock.

Be sure to reconnect both motor ground leads to the back of the panel
before reinstalling the panel.

Motor replacement is the reverse sequence of removal.

5.2.8 Impeller shaft replacement

5.2.8.1 Impeller Shaft Removal

1. Disconnect power to the wetside of the analyser.

2. Stop the flow of sample to the analyser.

3. Disconnect the sample and reagent tubing from the metering

pump inlet.

4. Remove the cell body, impeller, grit guard, cell sealing O-ring, and
seal adapter as described in paragraph 5.2.6, Impeller Shaft Seal
Replacement.

5. Remove the panel assembly from the mounting enclosure.

6. Disconnect the impeller motor grounding terminal.

7. Remove the impeller motor mounting screws and washers. Remove

the impeller motor.

8. Loosen the impeller shaft retaining setscrew using a 3/32-inch

Allen wrench.

9. Remove the impeller shaft from the coupling.

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 MICRO/2000® AND DEOX/2000® MODULE

5.2.8.2 Impeller Shaft Installation

1. If the impeller shaft coupling is removed from the impeller motor install
the coupling on the motor shaft against the front face of the motor.
Tighten the retaining setscrew (using a 3/32-inch Allen wrench).

2. Slide the impeller shaft into the coupling until it bottoms against the
end of the motor shaft. Tighten the retaining setscrew snugly (using
a 3/32-inch Allen wrench), about ¼ turn past the first resistance.

3. Mount the impeller motor on the back of the panel with the retaining
screws and washers.

4. Fasten the impeller motor grounding terminal (with pump motor

grounding terminal) on the back of the panel with the retaining
screw and serrated lockwasher.

5. Remount the panel in the mounting enclosure.

6. Reattach the sample and reagent tubing to the inlet of the metering pump.

7. Apply a small quantity of silicone grease to the O-ring and

impeller shaft.

8. Reinstall the seal adapter, grit guard, cell sealing O-ring, impeller,
and cell body and cell retaining screws, as described in paragraph
5.2.6, Impeller Shaft Seal Replacement - Installation of Shaft Seal.

5.2.9 Pump motor removal and replacement

1. Remove the panel assembly from the mounting enclosure. Refer

to paragraph 5.2.1, Wetside Panel Removal and Replacement.

2. Remove the pump rotor and thrust washer from the panel assembly.
Refer to paragraph 5.2.1, Pump Rotor, Rollers, and Thrust Washer
Removal and Replacement.

3. Disconnect the motor ground lead from the back of the panel.

4. Remove the two screws that mount the motor from the front of the panel.

5. Gently slide the motor out from the back of the panel. The motor
shaft has a sliding fit inside the ball bearing in the pump hub. If it
binds while trying to slide it out, check the exposed portion of the
shaft for dirt or scratches that may cause binding. Clean off the
dirt or carefully remove scratches with a fine file. The shaft can be
damaged by excessive filing.

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5.2.10 Probe electrolyte and electrodes

The analyser performs best when the probe is left undisturbed as much
as possible. Manual cleaning of the probe electrodes should not be done
unless necessary, as this will require recalibration of the analyser.

CAUTION : Do not sand the probe electrodes! The electrodes are made
of a thin film of platinum and cannot be replaced or repaired. If sanded,
this thin film of platinum will be quickly removed and the probe will no
longer function. If cleaning is necessary, a clean paper towel may be used.

Check the electrolyte level occasionally and maintain the level so that it
is at least visible through the clear section of the probe with the probe in
the installed position. If the electrolyte level drops noticeably in less than
a month, the porous element is leaking excessively. The porous element is
intended to allow a slight flow of electrolyte and excessive flow will not
harm the performance of the analyser unless the probe is allowed to run out
of electrolyte. If excessive use of electrolyte becomes a nuisance (requires
constant monitoring of the level), replace the porous element and check the
element bore for damage that would hinder the sealing around the element.

Also, check if the electrolyte has become contaminated. This is usually

indicated by a color change or by the electrolyte becoming watery. It
is not unusual for the electrolyte to become alternately cloudy and then
clear, this can be caused by changes in water or ambient temperature.

5.2.11 Probe cleaning, refilling and porous element replacement

The probe cannot be disassembled (all joints are cemented). It is not

serviceable except for the following maintenance operations.

NOTE: The analyser will perform best when the probe is left undisturbed as
much as possible.

Check the electrolyte level and refill as necessary.

Clean the electrodes by wiping blue abrasive paper or with a clean paper
towel. If there is a greasy film on the electrodes, this can be removed by
cleaning with a paper towel dipped in alcohol. If there are hard deposits
on the electrodes, this can be removed by wiping the electrodes with a
clean paper towel dipped in muriatic acid (10% hydrochloric acid). The
analyser will require recalibrations after 24 hours of operation after the
electrodes are cleaned.

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 MICRO/2000® AND DEOX/2000® MODULE

WARNING: Hydrochloric acid and muriatic acid will severely irritate

eyes and cause chemical burns to skin. Always wear appropriate protective
equipment during handling. When diluting acid, always pour acid into the
water, never pour water into acid. It is the responsibility of the user of the
equipment to obtain and follow the safety precautions of the manufacturer
of the hazardous material.

If the probe is to be stored for more than a week, the porous element should
be removed, the electrolyte drained, and the reservoir should be rinsed
with distilled water to eliminate any remaining electrolyte. Otherwise the
electrode end must be kept wetted to prevent crystallization of the electrolyte
in the pores of the element and clogging of the element.

The porous element can be removed and the electrolyte drained as follows:
Using a self-tapping screw (a #6 drywall screw is preferred), tap into the
porous element, then pull out the element. The element is approximately
6mm (¼-inch) long.This porous element is no longer usable. The electrolyte
will drain out slowly.Rinse the reservoir well with distilled water to remove
residual electrolyte. When removing the element in this manner, use care
not to scar the sides of the element bore as this might prevent insertion of a
new piece of porous material or cause excessive leakage of the electrolyte.

A new porous element can be created and installed as follows: Do not

precut the porous material to length. A clean, sharp razor blade is required
to make a clean cut in the porous material. First, using a sawing motion,
slice off a thin slice of one end of a length of the porous material. Press this
fresh cut end into the element bore. The fit should be snug. The material
should be embedded to a 6 to 9mm (¼" to 3/8") depth. Cut off protruding
portion of porous element flush with probe tip, being very careful not to
scratch or damage electrodes.

56 W3T331759 / WT.050.585.003.UE.IM.1014
 MICRO/2000® AND DEOX/2000® MODULE

6 I LLUSTRATIONS

List of Contents
Section
MICRO 2000 and DEOX 2000 CE Wetside
Enclosure Asssembly 50.580.000.035A&B
MICRO 2000 and DEOX 2000 Wetside
Casting Assembly 50.580.000.040A&B
Micro CE - DEOX 2000 wetside GAA1177 sheets 2 & 4
W3T108351 Waterline Kit. 50.580.000.050A&B
W3T98601 Reagent 50.505.020.010

W3T331759 / WT.050.585.003.UE.IM.1014 57
 MICRO/2000® AND DEOX/2000® MODULE

MICRO/2000® AND DEOX/2000® CE WETSIDE ENCLOSURE ASSEMBLY - PARTS —

W3T140748 (240V) W3T332446 (115V)

50.580.000.035A
ISSUE 2 7-14

58 W3T331759 / WT.050.585.003.UE.IM.1014
 MICRO/2000® AND DEOX/2000® MODULE

KEY PART NO. QTY. DESCRIPTION

1 W2T1535 1 Grounding lug
2 W2T504179 8 Bootlace ferrule, insulated, 1.5Mm
3 W3T160551 1 M20 cable gland
4 W2T416769 1 Cable gland nut
5 W2T416873 2 Din rail guide
6 W2T365250 1 1/4" Flat seat hose barb
7 W2T365251 4 Rivet
8 W2T416875 1 Capacitor, 15μf±20x, 100v
9 W2T416879 1 Enclosure mach'd
10 W2T416880 1 Capacitor, 10μf±20x, 100v
11 W2T416881 1 Facade, complete
12 W2T416882 1 Mach'd mounting plate
13 W2T365269 4 Mounting plate screw
14 W2T365269 1 10-32 Unc x 3/8 green ground screw
15 W2T366020 2 Mb3a10c2, cable mounts
16 W2T19230 2 Terminal block mounting screw
17 W2T375930 1 18 Awg stranded wire, black
18 W2T16189 1 18 Awg stranded wire, white
19 W2T19887 1 Shrink tubing, 0.46 Id bs
20 W2T11555 1 Warning label
21 W2T13305 1 Terminal block, captive wire
22 W2T421097 1 Strip, marker
23 W3T139780 1 Enclosure assembly, ce transformer

When ordering material always specify model and serial number of apparatus

MICRO/2000® AND DEOX/2000® CE WETSIDE ENCLOSURE ASSEMBLY - PARTS

LIST — W3T140748 (240V) W3T332446 (115V)

50.580.000.035B
ISSUE 1 2-11

W3T331759 / WT.050.585.003.UE.IM.1014 59
 MICRO/2000® AND DEOX/2000® MODULE

MICRO/2000® AND DEOX/2000® WETSIDE CASTING ASSEMBLY - PARTS

— W3T140748 (240V) W3T332446 (115V)

50.580.000.040B
ISSUE 3 7-14

60 W3T331759 / WT.050.585.003.UE.IM.1014
 MICRO/2000® AND DEOX/2000® MODULE

KEY PART NO. QTY. DESCRIPTION

1 W2T8855 1 Seal, adapter, pvc
2 W3T172188 1 Label, warning
3 W2T416867 1 Casting, al6061
4 W2T416872 1 Drip trough, pvc
5 W3T108352 1 Name tag
6 W2T416876 1 Motor, reversible, 600/500 rpm
7 W2T17575 2 Screw, #8-32 x 1/2" lg.
8 W2T375790 2 Bolt, 1/4-20 x 2-1/4" lg.
9 W2T19395 3 Set screw, #6-32 x 3/16" lg.
10 W2T17709 2 Ring terminal, blue
11 W2T17365 3 Clamp, plastic
12 W2T17476 2 Screw, #10-32 x 1/2" lg.
13 W2T376054 2 Screw, 1/4-20 x 1-1/4" lg.
14 W2T18721 2 Lockwasher, #8 internal type
15 W2T18998 2 Lockwasher, #6 internal type
16 W2T19844 4 Screw, #6-32 x 3/8" lg.
17 W2T15636 4 Lockwasher, 1/4"
18 W2T14421 2 Screw, #10-24 x 3/4" lg.
19 W2T13299 3 Clip, plastic
20 W2T12538 1 Bearing, pvc
21 W2T12112 1 U-cup, teflon
22 W2T418119 1 Seal, grit, teflon
23 W2T11682 1 Coupling, brass
24 W2T11674 1 Occlusion ring, teflon
25 W2T11675 1 Thrust washer, teflon
26 W2T11676 3 Pump roller, nylon
27 W2T11678 1 Impeller shaft, polyethylene
28 W2T376256 1 Impeller, pvc
29 W2T11680 1 Cell, e 796 tyril
30 W2T376260 1 Set screw, ss, #10-24 x 1/2" lg.
31 W2T376750 1 O-ring, (018), epr
32 W3T107925 1 Rotor body unit, steel
33 W3T107926 1 Tube unit, assembled
34 W2T11687 1 Ball bearing, steel, 1/4" id x 5/8" od
35 W2T291156 1 Label, notice
36 W2T416877 1 Motor, 1 rpm
W2T416878 1 Motor, 2 rpm (used in W3T980557, W3T98058 AND W3T98057)

When ordering material always specify model and serial number of apparatus

MICRO/2000® AND DEOX/2000® WETSIDE CASTING ASSEMBLY - PARTS LIST

— W3T140748 (240V) W3T332446 (115V)

50.580.000.040B
ISSUE 2 2-11

W3T331759 / WT.050.585.003.UE.IM.1014 61
62
FUNCTIONAL TESTS
After verifying the wiring is correct connect power.
Verify that the pump and impeller operate smoothly and quietly (indicating no mechanical problems)
Both motors should be turning counter-clockwise.

issue 6
NOTE: It is sufficient to note that the impeller appears to be turning rapidly. The pump motor will turn at 2 RPM

NOTE: Block the bypass flow from the Y-strainer on module mounted arrangements to reduce water flow
during testing. Connect (cold) water supply to the analyser inlet. Water supply should be set to
0.2 bar (3 PSI) - higher pressure may result in water spray in unit.
Connect reagent tubing to the inlet reagent fittings of the pump and place the inlet of these tubing
lengths (about 1.2m (4 feet)) in a reservoir of water (set at least 600 mm (2 feet) below the analyser
to test the priming capability).

GAA1177 sheet 2
Allow time for the pump sample and reagent tubing to prime
Inspect unit plumbing and tubing for leaks.

W2T416881 (AAD2585) W3T139777 (2 RPM) W3T140743

LISTED UNDER W3T140743 SCALE 0.333

MICRO CE - DEOX 2000 WETSIDE

MICRO/2000® AND DEOX/2000® MODULE

SCALE 0.500

W3T331759 / WT.050.585.003.UE.IM.1014
 1
3 U29399 W3T107927 REAGENT ASSEMBL Y HOSE NEOPRENE 1
2 RK634411 W2T11683 TUBI NG . 0 2 0 I . D. NEOPRENE 8 IN
1 P60424 W2T11670 TEE REDUCTION CONNECTOR KYNAR PVDF 1

ITEM PT NUM SAP NUM DESCRIPTION MATERIAL QTY

W3T108407(AAD3503) - 1 REAGENT PARTS GROUP

6 P60420 W2T11668 " Y" ADAPTER KYNAR PVDF 1

5 RK634411 W2T11683 TUBING .020 I.D. NEOPRENE 1 IN
4 RK634411 W2T11683 TUBING .020 I.D. NEOPRENE 1 IN
3 U29399 W3T107927 REAGENT ASSEMBL Y HOSE NEOPRENE 2
2 RK634411 W2T11683 TUBI NG . 0 2 0 I . D. NEOPRENE 8 IN
1 P60424 W2T11670 TEE REDUCTION CONNECTOR KYNAR PVDF 1

ITEM PT NUM SAP NUM DESCRIPTION MATERIAL QTY

W3T108408(AAD3506) - 2 REAGENT PARTS GROUP

6 P60420 W2T11668 " Y" ADAPTER KYNAR PVDF 1

5 RK634411 W2T11683 TUBING .020 I.D. NEOPRENE 1 IN
4 RK634411 W2T11683 TUBING .020 I.D. NEOPRENE 1 IN
3 U29399 W3T107927 REAGENT ASSEMBL Y HOSE NEOPRENE 2
2 RK634411 W2T11683 TUBING .020 I.D. ( SEE NOTE 1) NEOPRENE 6 FT
1 P60424 W2T11670 TEE REDUCTION CONNECTOR KYNAR PVDF 1
2 ITEM PT NUM SAP NUM DESCRIPTION MATERIAL QTY

W3T140966- DEOX REAGENT PARTS GROUP

W3T331759 / WT.050.585.003.UE.IM.1014
6
5

4 3

1
MICRO/2000® AND DEOX/2000® MODULE

W3T108357 (AAD2696) W3T139777 NOTE: 1 FOR DEOX REAGENT PARTS GROUP W3T140966
W3T108447 (AAD4079) W3T139778 COIL ITEM 0.6 - 1.8 m (2 - 6 FT) TUBING AND HANG OVER SAMPLE CELL

63
issue 6
GAA1177 sheet 4
MICRO CE - DEOX 2000 WETSIDE
 MICRO/2000® AND DEOX/2000® MODULE

KEY PART NO. QTY. DESCRIPTION

1 W2T19400 1 Reducing bushing, pvc, 1/4" x 1/2" npt
2 W2T16766 1 Nipple, pvc, 1/4" x 1/4"
3 W2T19799 1 Nipple, pvc, 1/2"
4 W2T14737 2 Elbow, pvc, 90°
5 W2T12055 2 Union nut, pvc, 1/2-20 thread
6 W2T16217 1 Tubing, polyethylene, 1/4" id, 3 ft
7 W2T15468 1 Valve, cci pvc
8 W2T13310 1 Y strainer, pvc
9 W2T12996 1 Labcock valve, pvc/epdm, 1/4" t x t
10 W2T378415 1 Ball valve, 1/2" single entry, pvc type

When ordering material always specify model and serial number of apparatus

W3T108351 WATERLINE KIT - PARTS LIST

50.580.000.050B
ISSUE 1 9-10

64 W3T331759 / WT.050.585.003.UE.IM.1014
 MICRO/2000® AND DEOX/2000® MODULE

W3T108351 WATERLINE KIT - PARTS LIST

50.580.000.050B
ISSUE 1 9-10

W3T331759 / WT.050.585.003.UE.IM.1014 65
 MICRO/2000® AND DEOX/2000® MODULE

10
5

KEY PART NO. QTY. DESCRIPTION

1  W2T11685 8' Tubing (.020 ID) norprene
2 W3T110057 1 Bottle
3 W2T11234 1 Rigid tubing (.027 ID), 13" lg.
5 W2T16958 2 1/4" lockwasher (SS)
6 W2T18825 2 Mach. Screw (rd.Hd.,SS) 1/4"-20 x 3/4" lg.
7 W2T417965 2 Hex. jam nut (SS) 1/4"-20
8 W2T14861 1 Strap
9 W2T13382 1 Bottom bracket shelf
10 W3T107927 1 Reagent tube unit
NOTE:  Not part of W3T98601.

When ordering material always specify model and serial number of apparatus.

W3T8601 REAGENT - PARTS

50.505.020.010
ISSUE 4 9-03

66 W3T331759 / WT.050.585.003.UE.IM.1014
 MICRO/2000® AND DEOX/2000® MODULE

7 COMPLETE DEVICES , RETRO FIT KITS & SPARE PARTS

List of Contents

PARA. NO.
Retrofit Sets 7.1
Spare Parts and Consumables 7.2
MICRO/2000® and DEOX/2000® Spare Parts 7.3

W3T331759 / WT.050.585.003.UE.IM.1014 67
 MICRO/2000® AND DEOX/2000® MODULE

7.1 Retrofit Sets

3-electrode cell MICRO/2000® 3-electrode cell DEOX/2000® with

with P T1000 P T1000
W3T158828 - Plug-in card with W3T158829 - Plug-in card with
terminals terminals
W3T158830 - with optional Process W3T158831 - with optional Process
Control Control

7.2 Spare Parts and Consumables

MICRO/2000® and DEOX/2000®

Electrode Electrolyte set Probe porous Probe:
cleaning sand W3T165565 junction material Std. range W3T99781
W3T100141 W2T12276 High range W3T99785

7.3 MICRO/2000® and DEOX/2000® Spare Parts List

Part No. Qty. Description

W3T107488 1 Preventive maintenance kit
W3T107926 s1 Sample tube assembly (Sample metering pump)
W3T107927 s2 Reagent tube assembly (Sample metering pump)
U10242 s1 Tube silicone grease (for impeller shaft seal)
W2T12538 s1 Bearing
W2T12112 s1 Impeller shaft seal
W2T11678 s1 Impeller shaft
W2T12113 s1 Fit guard, Impeller shaft
W2T376750 s1 O-ring (For cell, size #018, EPDM)
W2T11683 16 Ft Reagent tubing (yellow, 5/32" OD, Norprene)
W2T12617 4 Ft Sample tubing (black, 1/4" OD, Norprene)
W2T12016 2 Ft Sample tubing (translucent, 1/4" OD, LDPE)
W3T100141 1 Tube Tube grit
W2T12276 6 in. Probe junction material
W3T165565 1 Btl Probe electrolyte solution, 2 oz.
W2T416885 1 Fuse, 3 AG 1/4 Amp, 250 VAC
W2T416886 1 Fuse, 3 AG 1/2 Amp, 250 VAC
W3T108269 1 Abrasive paper (1" x 2")
W3T122322 1m DIN rail (39.37")
W2T492188 2 Fuse, 5 x 20mm, 200 mA, 250VAC

s Part of W3T107488 * Eight vials

68 W3T331759 / WT.050.585.003.UE.IM.1014
 MICRO/2000® AND DEOX/2000® MODULE

DEOX 2000 Old Part No New Part No.

Chemical pack Comprising: AAB1098 W3T291579
5 litres acetic acid U86584 W2T636701
5 litres de-ionised water U86586 W2T636702
Potassium iodide 250g AAA8160 W2T633474
Potassium iodate solution AAB1128 W2T633562

MICRO 2000 Old Part No New Part No.

Chemical pack Comprising: AAA7170 W3T291540
Sodium acetate buffer AAA6723 W2T633388
2.5 litres de-ionised water AAA6978 W2T633403
Potassium iodide 250g AAA8160 W2T633474

W3T331759 / WT.050.585.003.UE.IM.1014 69
 MICRO/2000® AND DEOX/2000® MODULE

70 W3T331759 / WT.050.585.003.UE.IM.1014
 MICRO/2000® AND DEOX/2000® MODULE

APPENDIX A
MICRO 2000 Reagents

List of Contents

MICRO/2000® Flow Block Theory of Operation 1

Preparation of Reagents - MICRO/2000® 2
Preparation of pH Buffer 2.1
Preparation of Potassium Iodide Solution
for MICRO/2000® 2.2
Preparation of Potassium Iodate 2.3
Refilling Reagent Reservoirs 3
Selection of Reagents 4
Residual Form 4.1
Chlorine dioxide and potassium permanganate
monitoring 4.1.1
Bromine residual monitoring 4.1.2
Chlorine residual monitoring 4.1.3
Free chlorine monitoring 4.1.4
Total chlorine monitoring 4.1.5
Interfering residuals 4.1.6

1 MICRO/2000® Flow Block Theory of Operation

The measurement of free chlorine is made directly at a buffered pH of 4 with

pH 4 buffer or pH of 5 or 6 with carbon dioxide. The measurement of total
chlorine is made by reacting the various chlorine species with potassium
iodide at the buffered pH, then measuring the resulting iodine concentration.

The analyser measuring process is as follows:

A continuous sample is delivered to the analyser. A flushing Y-strainer

divides the sample into two streams—the larger bypass stream continuously
flushes the Y-strainer and the smaller stream, about 500 ml/min, flows into
the analyser. Most of the flow into the analyser is again bypassed, but a
small portion (15 ml) is metered from this flow by a peristaltic metering
pump. The reagents, pH 4 buffer or carbon dioxide for the measurement of
free chlorine residual and potassium iodide solution with detergent for the
measurement of total chlorine residual, are also metered by the same pump.
The reagents are then mixed with the sample as the sample is pumped to
the analyser cell. A three-electrode amperometric “probe” is immersed in
the sample in the cell. A rotating impeller stirs the sample and maintains a
constant sample velocity across the electrode surfaces. It also agitates the
grit used to clean deposits from the electrodes, improving the stability of
calibration. The amperometric cell produces a signal (electrical current)
proportional to the oxidant (e.g., chlorine) concentration in the cell.

W3T331759 / WT.050.585.003.UE.IM.1014 71
 MICRO/2000® AND DEOX/2000® MODULE

2 Preparation of Reagents - MICRO/2000®

WARNING: Wear recommended protective eyewear when servicing

the wet components of the analyser, particularly when servicing reagents
and reagent lines. The analyser uses chemicals that can cause severe
personal injury by chemical burns on contact with eyes. Rinse any area
of contact immediately. If chemicals contact eyes, rinse from eyes and
seek immediate medical attention.

WARNING: pH4 buffer and acetic acid will severely irritate eyes and cause
chemical burns to skin.Always wear appropriate protective equipment during
handling. When diluting acid, always pour the acid into the water, never pour
water into acid. Use caution when disconnecting the reagent tubing and avoid
contact with any fluid that drips from the open end. It is the responsibility
of the user of the equipment to obtain and follow the safety precautions of
the manufacturer of the hazardous material.

Chemicals for industrial use: vapour may be harmful if inhaled and

may be fatal if swallowed. Liquid may cause severe burns to skin and
eyes. Avoid contact with eyes, skin, or clothing. Wash thoroughly after
handling. In case of spill, soak up with sand or earth.

When servicing liquid reagent lines, pumps, or refilling reservoirs, turn

off pumps to avoid possible squirting of reagent. Observe all safety
precautions recommended by the reagent manufacturer or supplier.

WARNING: Handle in accordance with manufacturer’s recommendations.

Do not mix with other chemicals. Dispose of any chemicals in accordance
with all applicable federal, state and local environmental regulations.

The type and number of reagents are determined by the specific application
and residual requirements.

2.1 Preparation of pH4 Buffer

This reagent is available from Evoqua Water Technologies premixed in

one gallon plastic bottles. It may also be made on-site as follows: dissolve
919 grams of sodium acetate, trihydrate in approximately 1.5 litres of
distilled water, then mix with 1.73 litres of glacial acetic acid and dilute
with distilled water to obtain one gallon of reagent solution.

WARNING: Glacial acetic acid will severely irritate eyes and cause chemical
burns to skin.Always wear appropriate protective equipment during handling.
When diluting acid, always pour acid into water, never pour water into acid.
It is the responsibility of the user of the equipment to obtain and follow the
safety precautions of the manufacturer of the hazardous material.

72 W3T331759 / WT.050.585.003.UE.IM.1014
 MICRO/2000® AND DEOX/2000® MODULE

2.2 Preparation of Potassium Iodide Solution For MICRO/2000®

NOTE: Potassium iodide solution is used only in the measurement of

total chlorine. Therefore, this section does not apply to analyzers installed
to measure free chlorine or potassium permanganate.

Potassium iodide (KI) is added to distilled water and fed into the water
sample by the metering pump when measuring total chlorine. The KI
reacts with the various forms of chlorine present to release a proportional
amount of iodine. The amount of KI required is dependent upon the
maximum range of the analyser.

The quantity of KI required is calculated as follows:

50 + (4 * range) = grams KI
Example: Analyser range: 5 mg/l

50 + (4 * 5) = 70 grams KI

CAUTION: Never mix potassium iodide (KI) with sulphuric acid, as

free iodine will form immediately.

KI (g/2.5 litre bottle)

Analyser range (mg/l) KI (g/l)
Specific Amount Typical Amount
0 - 0.5 32 80
0 - 1.0 32 80 100g
0 - 2.0 35 87.5
0 - 5.0 41 102.5
0 - 10 50 125 200g
>10 80 170

KI either in tablets or in granular form may be used. When using auxiliary

KI tablets (W2T614371), one tablet equals 3 grams.

2.3 Preparation of Potassium Iodate

Dissolve the correct amount of Potassium Iodate into one gallon of

pH4 buffer solution (see chart).

RANGE PACKAGE NO. ADD NO. VIALS

± 0.5 mg/l W2T8468 - 3 grams 1
± 1.0 mg/l W2T8468 - 3 grams 2
± 2.5 mg/l W2T8469 - 15 grams 1
± 5.0 mg/l W2T8469 - 15 grams 2
± 10.0 mg/l W2T8469 - 15 grams 4

W3T331759 / WT.050.585.003.UE.IM.1014 73
 MICRO/2000® AND DEOX/2000® MODULE

3 Refilling Reagent Reservoirs

WARNING: To avoid possible severe personal injury or equipment

damage, observe the following:

pH4 buffer and acetic acid will severely irritate eyes and cause chemical
burns to skin. Always wear appropriate protective equipment during
handling. When diluting acid, always pour the acid into the water, never
pour water into acid. Use caution when disconnecting the reagent tubing
and avoid contact with any fluid that drips from the open end. It is the
responsibility of the user of the equipment to obtain and follow the safety
precautions of the manufacturer of the hazardous material.

Chemicals for industrial use: vapour may be harmful if inhaled and

may be fatal if swallowed. Liquid may cause severe burns of skin and
eyes. Avoid contact with eyes, skin, or clothing. Wash thoroughly after
handling. In case of spill, soak up with sand or earth.

To avoid cross contamination of the reagents, always use each reservoir

for the same reagent. The reservoirs should be clearly labelled with the
name of the reagent they contain. To fill reagent reservoirs, loosen and
move or remove the threaded cap on the reservoir. Use a funnel when
filling reagent reservoirs. The use of a funnel allows the reservoir to be
filled without removing the rigid length of tubing from the reservoir. If
the tubing is removed from the reservoir, keep it clean. Dirt can clog the
tubing. If the tubing is removed from the reservoir while the metering
pump is operating, air is drawn into the tubing. This causes a momentary
disruption of service until the tubing is returned to the reservoir and the
inducted air is purged from the tubing and pump.

4 Selection of Reagents

The MICRO/2000® Residual Analyser allows the flexibility to select

from several analyser sample conditioning chemicals (reagents). The
choice of conditioning chemical is made to provide the best analyser
performance while considering chemical cost and handling requirements.
Some applications require no chemical conditioning of the analyser sample,
while others may require a combination of chemicals. Sample conditioning
may be used to provide a stable condition for residual measurement, to
eliminate interference from background residuals that are not of interest, and
to chemically convert residuals to a form that is conveniently measurable
by the analyser. More specifically, the choice of chemicals for analyser
sample conditioning in a given application is based on three parameters;

• the residual to be monitored

• other (potentially interfering) residuals present
• water pH and alkalinity

74 W3T331759 / WT.050.585.003.UE.IM.1014
 MICRO/2000® AND DEOX/2000® MODULE

4.1 Residual Form

4.1.1 Chlorine dioxide and potassium permanganate monitoring

The stability of the sample pH is not as critical when monitoring chlorine

dioxide and potassium permanganate residuals as when measuring chlorine
residuals. A sample pH change of 0.2 pH units between calibration will
cause less than 5% error. Response to chlorine dioxide is somewhat
improved at lower pH, however, and for best accuracy (stability) in the
monitoring of both residuals, carbon dioxide gas buffering of the analyser
sample is recommended. Carbon dioxide will also help prevent deposits
caused by water hardness within the wetted analyser components.

4.1.2 Bromine residual monitoring

Bromine residuals are often encountered in chlorinated water with a

significant bromide residual (e.g. in saline waters). Bromine residual
behaves very similarly to chlorine residual and so the application
recommendations for each are the same.

4.1.3 Chlorine residual monitoring

For the purpose of this description, chlorine species can be grouped as

follows:

a. Free chlorine - hypochlorous acid and hypochlorite ion

b. Chloramines - monochloromine and dichloramine

c. Organic chlorine - a broad group of compounds with relatively

weak disinfecting and oxidizing potential, a byproduct of
chlorination

d. Total chlorine - the sum of the above residuals

4.1.4 Free chlorine monitoring

In applications where the pH is less than pH8 an is stable, free chlorine

residual can be monitored with no chemical conditioning. Often the
stability of the water sample pH is not certain and a buffer is used to
regulate the analyser sample pH of between pH6 and pH4. If it is important
that the analyser function accurately under conditions where the pH of
the water sampled may vary, buffering is recommended.

W3T331759 / WT.050.585.003.UE.IM.1014 75
 MICRO/2000® AND DEOX/2000® MODULE

4.1.5 Total chlorine monitoring

Potassium iodide liquid reagent must be added to the analyser sample

for the measurement of total chlorine residual. The sample pH should be
maintained between 4.0 and 4.7. The iodide solution is made by adding
potassium iodide to one gallon of unchlorinated DI water.

4.1.6 Interfering residuals

Interfering residuals can cause either positive interference (strong

oxidants) or negative interference (e.g. organics that combine with
chlorine to form organic forms, some of which can behave as free chlorine
or may not be detected at all by the standard method of measurement
or by the analyser). Decreasing the analyser sample pH (e.g. from pH4
to pH2.5) may, in some applications, cause interference from oxidants
but, where acceptable, may also be desirable to improve the response to
sluggish organic chlorine compounds in the measurement of potassium
permanganate or chlorine dioxide residuals, ammonium sulphate reagent
liquid is used to eliminate the response (interference) to free chlorine when
necessary. The MICRO 2000 Residual Analyser allows the flexibility to
select from several analyser sample conditioning chemicals (reagents).
The choice of conditioning chemical is made to provide the best analyser
performance while considering chemical cost and handling requirements.
Some applications require no chemical conditioning of the analyser
sample while others may require a combination of chemicals. Sample
conditioning may be used to provide a stable condition for residual
measurement, to eliminate interference from background residuals which
are not of interest and to chemically convert residuals to a form which
is conveniently measurable by the analyser.

Specifically, the choice of chemicals for analyser sample conditioning

in a given application is based on three parameters - the residual to be
monitored, other (potentially interfering) residuals present and water
pH and alkalinity.

76 W3T331759 / WT.050.585.003.UE.IM.1014
 MICRO/2000® AND DEOX/2000® MODULE

APPENDIX B
DEOX/2000® Reagents

List of Contents

DEOX/2000® Theory of Operation 1

Preparation of Reagents - DEOX/2000® 2
Preparation of Potassium Iodide Solution
for DEOX/2000® 2.1

1 DEOX/2000® Theory Of Operation

When a process requires super chlorination the effluent from it will have
to be dechlorinated to some extent to allow discharge, either to a sewer
or a natural water source. A variety of methods are available for de-
chlorination depending on the concentration of chlorine to be removed,
the most common being the reaction of chlorine species in the water with
sulphur dioxide (SO2) or sodium bisulphite (NaHSO3)

A range of chlorine species is typically present in industrial processes,

these ranging from hypochlorous acid (HOCl) to combined chlorine such
as chloramines. The reaction with SO2 for these species is indicated below.

The initial step is for the formation of sulphurous acid:

SO2 + H2O ------> H2S03

This reacts with chlorine species as follows:

HOCl + H2SO3 ------> HCl + H2SO4

NH2Cl + H2SO3 + H2O ------> NH4Cl + H2SO4

NHCl2+ 2H2SO3 + 2H2O ------> NH4Cl + 2H2SO4

This reaction with sodium bisulphite is

Cl2 + NaHSO3 + H2O ------> NaSO4 + 2HCI

The reactions show that both free and combined chlorine can be removed.
Dechlorination byproducts are ammonium chloride (NH4Cl), a salt,
hydrochloric acid (HCl) and sulphuric acid (H2SO4). These are naturally
neutralised by calcium carbonate (CaCO3) in the water, the result being
a reduction in the hardness of the water. When S02 is used each mg/l of
chlorine removed results in 2.8mg/l of hardness reduction and when

W3T331759 / WT.050.585.003.UE.IM.1014 77
 MICRO/2000® AND DEOX/2000® MODULE

NaHSO3 is used, 1.38 mg/l of hardness is removed. The stoichiometric

relationship means that for every mg/l chlorine, 0.9 mg/l SO2 is required
(often this is increased to 1.05 to eusure complete dechlorination) while for
sodium bisulphite, 1.46 mg/l must be used. The alkalinity of chlorinated
wastewater effiuent is usually in the region of 150 to 200 mg/l as CaCO3.
Therefore if S02 is used, dechlorination of 10 mg/l would result in a
28 mg/l reduction in alkalinity, and for NaHSO3, the result would be
14 mg/l reduction.

The process has to be controlled by a dechlorination monitor. This can be

done in a number of ways. A traditional chlorine monitor can be used to
control the process to zero chlorine residual. The disadvantage with this
approach is that the monitor only responds to the chlorine residual and not
SO2. Hence the zero of the instrument is zero chlorine, addition of SO2
beyond this will not be detected and there is a possibility of excessively
dosing SO2, especially if there is a long process time.

An alternative approach is to use a centre zero analyser such as the SFC

DEOX/2000®. In this approach an iodine bias is applied to the cell.
Iodine (I2) is reduced in the cell analogous to chlorine Cl2 and hence a
zero current is established. The presence of chlorine results in both the
I2 and the Cl2 being reduced which creates a current greater than the zero
current. The presence of SO2 results in a reaction with I2 which decrease
the I2 bias in the cell. This yields a current lower than the zero current.
This is achieved by the following chemistry.

Iodine is not stable long term and hence has to be generated in the cell.
Using a peristaltic pump, Potassium Iodate (KIO3) and an excess of
Potassium Iodide (KI) are mixed in a acid solution.

KIO3 + 5KI+ 6HAc ------> 312 + 6KAc + 3H2O

This is constantly fed to the cell to create the zero current bias, the feed
rate being 0.08 ml/min of reagents in total, i.e. negligible compared to
the volume of water being treated.

The reactions are then as follows:-

If excess chlorine is present, this reacts with excess KI in the analyser

as follows:-

HOCl +2I-------> I2 + Cl- + OH-

Every mg/l of chlorine produces an extra mg/l of I2 which adds to the

zero current signal.

78 W3T331759 / WT.050.585.003.UE.IM.1014
 MICRO/2000® AND DEOX/2000® MODULE

If excess SO2 is present, this reacts as follows:-

SO2 + H2O ------> H2SO3

H2SO3 + H2O + I2 ------> H2SO4 + 2HI

Every mg/l of SO2 reacts with a mg/l of I2 and reduces the zero current
signal. These reactions are illutrated in the following graph.
100

80
current (µA)

60

40

20

0 2 4 6 8 10
mg/l Cl2 mg/l Cl2 / mg/l SO2
mg/l SO2
l2 Zero current

2 Preparation of Reagent DEOX/2000®

WARNING: Wear recommended protective goggles when servicing the

wet components of the analyser, particularly when servicing reagents and
reagent lines. The analyser uses chemicals that can cause severe personal
injury by chemical burns on contact with eyes. Rinse any area of contact
immediately. If chemicals contact eyes, rinse with copious amounts of
water and seek immediate medical attention.

WARNING: pH4 buffer and acetic acid will severely irritate eyes and cause
chemical burns to skin. Always wear appropriate protective equipment
during handling. When diluting acid, always pour the acid into the water,
never pour water into acid. Use caution when disconnecting the reagent
tubing and avoid contact with any fluid that drips from the open end. It
is the responsibility of the user of the equipment to obtain and follow
the safety precautions of the manufacturer of the hazardous material.

WARNING: Chemicals for industrial use: vapour may be harmful if

inhaled and may be fatal if swallowed. Liquid may cause severe burns to
skin and eyes. Avoid contact with eyes, skin, or clothing. Wash thoroughly
after handling. In case of spill, soak up with sand or earth.

W3T331759 / WT.050.585.003.UE.IM.1014 79
 MICRO/2000® AND DEOX/2000® MODULE

WARNING: When servicing liquid reagent lines, pumps, or refilling

reservoirs, turn off pumps to avoid possible squirting of reagent. Observe all
safety precautions recommended by the reagent manufacturer or supplier.

2.1 Preparation of Potassium Iodide Solution for DEOX/2000®

Potassium Iodide (KI) solution is prepared by dissolving 166g KI in 5

litres of distilled water. The Potassium Iodate (KI03) reagent is prepared
by adding KI03 concentrate to the Acetic acid. The table below is used
to determine the quantity.

Measuring Range Volume of KI03 (mls)

±0.5mg/l 50
±1.0 mg/l 100
±2.mg/l 250

The reagents are placed in the cabinet and one reagent tube is placed
in the KI solution whilst the other is placed in the Acetic acid solution.

NOTE: If the bias cannot be achieved add an additional 20% of the

Iodate standard.

80 W3T331759 / WT.050.585.003.UE.IM.1014
Evoqua Water Technologies
Aftermarket Support and Service
INTRODUCTION

Every day, millions of people and thousands of companies rely on Evoqua CO-ORDINATION
Water Technologies to help them meet their needs for clean water. Evoqua Water Technologies dedicated
Customer Service Department is
As the leading global provider of chemical dosing, metering, disinfection, co-ordinated from our Derby office.
chlorination, filtration, deionisation and electrochlorination products, Evoqua
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treatment in the municipal, industrial and the leisure industries.
[email protected]

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Meeting our customers needs is our highest priority. In addition to supplying

COMMISSIONING
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service options. Our dedicated team of highly skilled engineers are committed
to providing a first class service to our customers. Following installation, our team of
commissioning engineers are
responsible for the safe handover of
Getting the correct level of aftermarket support and service can ensure that your the equipment from ourselves to the
plant runs as efficiently as possible by preventing breakdowns and minimising new owner guaranteeing its
plant downtime. operability in terms of performance,
reliability and safety.
Our modular flexible approach ensures that our aftermarket support and service
offering can be tailored to meet your exact requirements, our offering includes:-
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Our skilled engineers carry work in all industries

including; life sciences, food & beverage and
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D
E

TRAINING
E Evoqua Water Technologies understands the
importance of training to our customers; receiving the
correct training can ensure that you get the optimum
performance out of our equipment and your plant.
F C

Our team of qualified trainers can put together

B bespoke training solutions tailored to suit your needs.
A
This could either be classroom based, or hands-on
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locations around the country.

FULL COVERAGE UK & IRELAND We have also found training creates stronger
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Over the years we have been able to grow our aftermarket opportunity to understand each others requirements.
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Evoqua Water Technologies have service centres all over
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E- Belfast, Northern Ireland evoqua.com 6597
F - Limerick, Ireland Canada canadainfo@ +1 905 944 2800
evoqua.com

Did you know? Germany wtger@ +49 8221 9040

evoqua.com
Evoqua Water Technologies has over 200 current Singapore infosg@ +65 6830 7100
service and maintenance contracts in mainland UK &
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Ireland and carry out over 2000 site vists per year
USA wtus@ +1 856 507 9000
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UK info.uk@ +44 0845 450
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All information presented herein is believed reliable and in accordance with accepted engineering practices. Evoqua makes no
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© 2014 Evoqua Water Technologies Ltd Subject to change without notice